Simulation method and apparatus for use in enterprise controls

ABSTRACT

A method used with a simulator and a controller, the controller running execution code to provide output signals which, when linked to resources, cause the resources to cycle through requested activities, the simulator receiving controller output signals and, in response thereto, generating motion pictures of resources as the resources cycle through requested activities, the simulator using data structures which model the resources to determine which motion pictures to generate, the method for generating execution code and data structures for use by the controller and the simulator, respectively, and comprising the steps of, for each resource, encapsulating resource information including resource logic in a control assembly (CA), instantiating at least one instance of at least one CA, compiling instantiated CA instance resource logic to generate execution code, gleaning simulation information from the instantiated CA instances and using the gleaned simulation information to generate a simulation data structure for the resources corresponding to the instantiated CA instances.

The present application is a continuation in part of U.S. patentapplication Ser. No. 09/075,122 which was filed on May 8, 1998 and whichissued as U.S. Pat. No. 6,161,051 on Dec. 12, 2000.

COPYRIGHT NOTIFICATION

Portions of this patent application contain materials that are subjectto copyright protection. The copyright owner has no objection to thefacsimile reproduction by anyone of the patent document, or the patentdisclosure, as it appears in the Patent and Trademark Office.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

This invention generally relates to improvements in computer systems,and more particularly, to system software for managing the design,simulation, implementation and maintenance of a manufacturing process.

A visit to virtually any modern manufacturing facility in the worldleaves room for little doubt that assembly and machining lines havebecome an integral part of the manufacturing process. Robots, computers,programmable logic controllers, mills, drills, stamps, clamps, sensors,transfer bars, assemblers, etc., are more numerous than people in mostmodern manufacturing facilities. This is because almost every industryhas recognized that use of automated assembly and machining lines toform and assemble product components and assemblies reducesmanufacturing time, reduces product costs and increases product quality.Hereinafter, automated assembly and machining will be referred tocollectively as automated manufacturing.

Unfortunately, while automated manufacturing has a large number ofadvantages, such manufacturing also has a number of shortcomings. Inparticular, the process (hereinafter “the development process”) ofdesigning, constructing and debugging a manufacturing process has alarge number of shortcomings. To understand the shortcomings of thedevelopment process, it is helpful to consider an exemplary developmentprocess. To this end, an exemplary development process will be describedin the context of developing a manufacturing line for producing a basicautomobile door frame assembly (i.e. the door without the window, windowmotors, activation buttons and other trim components).

To this end, initially a body engineer designs a door assembly based onexperience of parts, structural knowledge and welding information. Tofacilitate the door frame design process a body engineer typically usesa standard computer aided design (CAD) package (e.g. CATIA,Pro-Engineer, etc.). Using such a package the body engineer can changeframe dimensions, component thicknesses, rivet numbers, angles, theshapes of curved surfaces and so on.

A. The Development Process

From beginning to end, including the skills of a body engineer, thedevelopment process required to design, build and debug an automatedmanufacturing line involves no less than four separate engineeringdisciplines, each of which has a different set of required engineeringskills. The three disciplines in addition to body engineering includeprocess engineering, mechanical engineering, controls engineering andmanufacturing engineering.

Once the door frame assembly has been designed, the frame designinformation is given to a process engineer. The process engineer designsa process which will be required to manufacture the door frame assembly.To this end, the process engineer translates management numbers forfinished door frame assemblies into a high-level process of actions andresources based on acquired experience. When specifying the high-levelprocess the process engineer specifies required manufacturing tools(e.g. robots, clamps, workcells, etc.).

This tool defining process, like the door frame design process, has beenstreamlined by use of computer aided manufacturing (CAM) softwarepackages which enable a process engineer to virtually specify differentmechanical tool types and tool configurations including clamps, robots,mills, drills, assemblers, etc. which can be used to actuallymanufacture the door frame assembly. Sometimes a tool library will beprovided in a CAM package which includes commonly used mechanical tools,the mechanical tools selectable for reuse when required. Where arequired tool is not provided in a library, the CAM package and or CADpackage can be used to design the required mechanical tool for use inthe door frame manufacturing process and for storage in the library forsubsequent use if desired.

In addition to specifying the mechanical tools, the process engineer mayalso specify mechanical tool movements required during the manufacturingprocess. For example, for a clamp, the process engineer may specify anopen position and a closed position and thereby may define a range ofmovements therebetween. This ability to specify tool actions allows aprocess engineer to build a model of a mechanical tool in software suchthat the model has both static and kinematic characteristics. Thevirtual tool can then interact with other parts in an automated virtualmanufacturing process in the time dimension.

Moreover, the process engineer also specifies mechanical tool timing andsequencing via either a bar chart timing diagram, a flow chart or someother suitable sequence specifying tool. This sequencing informationindicates the sequence of tool movements during the automatedmanufacturing process. Furthermore, the process engineer specifiesresources and goals to drive the manufacturing process and may attemptto generate a cost justification for the frame assembly manufacturingprocess.

Hereinafter, the term “mechanical resources” will be used to refergenerally to the manufacturing tools which are specified by a processengineer and the specified tool movements will be referred to as“behavior”. In addition the information as a whole provided by theprocess engineer will be referred to as “process information”.

Next a control engineer receives the process information and, based onexperience, uses the process information to select control mechanismsand determines how to configure the mechanisms for controlling themechanical resources. The control system includes at least one PLC (i.e.a controller), sensors and actuators and electrical lines and hydraulictubing for linking the PLC to the actuators and sensors. The actuatorsand sensors are control mechanisms.

The actuators are eventually linked to the mechanical resources formotivating the mechanical resources in a manner consistent with theprocess information. Sensors are eventually linked to mechanicalresources or are positioned adjacent mechanical resources and indicatean instantaneous condition (e.g. the position of a resource, thetemperature of a liquid, the position of a work item—the upper leftcorner of a door frame, etc.) in the manufacturing process.

In addition, the control engineer has to integrate the mechanicalsequencing information, causal relationships, a Human Machine Interface(HMI), I/O tables and safety and diagnostic information into the controlsystem design. To aid in the process of selecting and configuringcontrol devices to control the mechanical resources and to provide ablue print for subsequent assembly of the control system, the controlengineer also generates a control system schematic with representationsof each control device and electrical and hydraulic links betweendevices and the PLC. Hereinafter the information provided by the controlengineer will be referred to as “controls information”.

Next, a manufacturing engineer receives the controls information and theprocess information, uses the process information to construct the linevia specified mechanical resources, uses the controls information toconstruct the control system and links the control system to themechanical resources.

After the line is completely developed, the control engineer furthergenerates execution code to execute on the PLCs to implement theautomated manufacturing processes. Then a control engineer performstests on line tools to identify execution code bugs in the systemdesign. For example, the control engineer may check to determine if arobot arm will crash into a work item on a transfer bar during aspecified tooling process or if a sensor is operating properly to detectthe presence of a clamp during a clamp extending movement. While anengineer other than the control engineer may be able to debug specificsystems, in most cases the control engineer is required for thedebugging process. This is because any change in the system may ripplethrough other parts of the control process which are not intuitive andwhich may only be known to the control engineer. In most cases many bugsshow up during this debugging process and therefore this step in theautomated manufacturing process is extremely tedious. This isparticularly true in automated manufacturing which requires complexcontrol systems.

Hereinafter, the separate sub-processes of the development process whichare performed by the separate engineers will be referred to as “processphases”.

B. Development Process Shortcomings

The above described development process has a large number ofshortcomings. First, the development process is extremely timeconsuming. In fact, the typical time required for designing, building,testing and reworking a simple manufacturing line is often months andthe time required for a relatively complex line often takes years of manhours. In many industries the import of time is exacerbated bycompetitive product cycles where getting a new product to market beforea competitor is crucial to a companies competitive posture. For example,in the automotive industry fresh styling is extremely important toentice product turnover.

Second, while some of the development process phases have beenstreamlined using design software (e.g. CAD and CAM are used to design adoor frame assembly and the mechanical tools required to construct theframe assembly), other process phases are not streamlined. This isparticularly true of the PLC logic programming process.

While the industry is starting to employ various programming languages,most industrial PLCs are still programmed in Ladder Logic (LL) whereinstructions are represented graphically by “contacts” and “coils” ofvirtual relays connected and arranged in ladder-like rungs across powerrails. LL, with its input contacts and output coils, reflects theemphasis in industrial control on the processing of large amounts ofinput and output data.

LL also reflects the fact that most industrial control is “real time”;that is, an ideal industrial controller behaves as if it were actuallycomposed of multiple relays connected in parallel rungs to provideoutputs in essentially instantaneous response to changing inputs.Present industrial PLCs do not, in fact, employ separate parallelrelay-like structures, but instead simulate the parallel operation ofthe relays by means of a conventional Harvard or Von Neumann-typecomputer processor which executes instructions one at a time,sequentially. The practical appearance of parallel operation is obtainedby employing extremely fast processors in the execution of thesequential control program.

As each rung is executed, inputs represented by the contacts are readfrom memory (as obtained from inputs from the controlled process or theprevious evaluation of coils of other rungs). These inputs are evaluatedaccording to the logic reflected in the connection of the contacts intoone or more branches within the rungs. Contacts in series across a rungrepresent boolean AND logic whereas contacts in different branches andthus in parallel across a rung represent boolean OR logic.

Typically a single output coil at the end of each rung is set or reset.Based on the evaluation of that rung, this setting or resetting isreflected in the writing to memory of a bit (which ultimately becomes anoutput to the industrial process or to another LL rung).

Once a given rung is evaluated the next rung is evaluated and so forth.In the simplest form of LL programming there are no jumps, i.e. allrungs are evaluated in a cycle or “scan” through the rungs. This is incontrast to conventional computer programming where branch and jumpinstructions cause later instructions or groups of instructions to beskipped, depending on the outcome of a test associated with those branchor jump instructions.

While LL is well suited for controlling industrial processes like thosein the automotive industry, LL programming is not an intuitive processand, therefore, requires highly skilled programmers. Where hundreds ofmachine tool movements must be precisely synchronized to provide amachining process, programming in LL is extremely time-consuming. Thetime and relative skill associated with LL programming together accountfor an appreciable percentage of overall costs associated with a controlsystem.

Industry members have made several attempts to streamline the logicprogramming process. One way to streamline any type of programming is toprovide predefined language modules, expressed in a language such as LL,which can be used repetitively each time a specific function isrequired. Because of the similar types of tools and movements associatedwith different mechanical tools, industrial control would appear to bean ideal industry for such language modules.

The predefined logic module approach works quite well for certainapplications, like small parts-material handling or simple machining.The reason for this is that the LL required for these applications tendsto be very simple. In small parts material handling applications the I/Ocount is low and the interfaces between modules are minimal. In fact,the mechanisms are often independent units, decoupled from neighboringmechanisms by part buffers such that no signals are required to beexchanged between modules. These “loosely coupled” systems lendthemselves to “cut and paste” programming solutions.

Unfortunately the predefined, fixed logic module approach does not workwell for other applications, for example metal-removing applications.There are several reasons for this. First, there can be considerablevariation in how components, such as sensors and actuators, combine toproduce even simple mechanisms. Second, processes like metal removingnormally require tightly controlled interaction between many individualmechanisms. Exchanging signals called interlocks between the controllogic modules of the individual mechanisms control the interaction. Theapplication of specific interlocks depends on knowledge of the processand the overall control strategy, information not generally needed orknowable when the control logic for each mechanism is defined.

For example, a drill is a typical metal-removing tool used in theautomotive industry. In this example an ideal drill is mounted on acarriage that rides along a rail between two separate limiting positionson a linear axis, an advanced position and a returned position. Twolimit switches, referred to herein as returned and advanced LSs, arepositioned below the carriage and, when tripped, signal that the drillis in the returned and advanced positions, respectively. Two separatedogs (i.e. trigger extensions), an advanced dog and a returned dog,extend downwardly from the bottom of the carriage to trip the LSs whenthe advanced and returned positions are reached, respectively. In theideal case, both LSs may be assumed to be wired in the same “normallyopened” manner, so that electrically speaking they are open whenreleased and closed when triggered. In this ideal case, where thephysical characteristics of the switches are limited, a single LL logicrung can determine when the drill is in the returned position andanother rung can determine when the drill is in the advanced position.

Unfortunately, in reality, there are electrically two types of LSs, oneLS type being wired normally opened and the other type wired normallyclosed. Furthermore, any LS can be mechanically installed in atripped-when-activated configuration, or a released-when-activatedconfiguration. All combinations of these types are used for varioustypes of applications. Thus, application requirements may demand controllogic capable of handling any configuration of LS types.

Simple mathematics demonstrates that with two different electrical typesof LSs and two mechanical configurations, there are sixteen possibleconfigurations of a two-position linear slide. Consider the languagemodules required to implement position logic for all theseconfigurations. To accommodate all sixteen-switch configurations, therecould be sixteen different language modules, each containing fixed LLlogic, and each named for the case it could handle. In this case, therewould be duplicate logic under different names. Alternatively, fourunique language modules could be provided, but then the user would havedifficulty identifying which of the sixteen physical configurations thatthe four modules could handle.

Clearly, even for a simple drill mounted on a two position linear slide,application variables make it difficult to provide a workable library offixed language modules. Adding more switches to the linear slide onlyincreases, to an unmanageable level, the number of language modulesrequired in the library.

Moreover, the contents of a complete language module for a drill mustalso consider other variables. These variables include, for example, thenumber and type of actuators required; the type of spindle, if any;whether or not a bushing plate is required; what type of conveyor isused; whether or not the drill will include an operator panel to enablelocal control. If an operator panel is included, what type of controls(i.e. buttons, switches and indicator lights) are required, just to namea few. Each tool variable increases the required number of unique LLmodules by more than a factor of two, which makes it difficult at bestto provide an LL library module for each possible drill configuration.

Taking into account the large number of different yet possiblemachine-line tools, each tool having its own set of variables, the taskof providing an all-encompassing library of fixed language modulesbecomes impractical. Even if such a library could be fashioned, the taskof choosing the correct module to control a given tool would probably bemore difficult than programming the required LL logic from scratch.

For these reasons, although attempts have been made at providingcomprehensive libraries of fixed language modules, none has provenparticularly successful and much LL programming is done from scratch.

Third, the process of generating schematic control diagrams is extremelylabor intensive and thus time consuming. This is because most schematiccontrol diagrams have to be constructed by hand linking electrical andhydraulic lines from one control mechanism to another, from devices to aPLC representation, linking control devices to mechanical tools and soon.

To reduce the time required to generate control system schematics, mostcontrol engineers now use one or more commercially available CAD systemsspecifically designed for generating schematic designs. These CADsystems enable an engineer to select standard representations forspecific control mechanisms and enable relatively quick electrical andhydraulic linking representations to be generated. Nevertheless, theseCAD systems can result in erroneous connection specification as acontrol engineer makes the decisions about how to link controlmechanisms. This is particularly true in the case of a large controlsystem where only a small portion of the entire control system can beviewed on a work station screen at one time. In this case, thepossibility of linking electrical and hydraulic lines incorrectly isexacerbated. Moreover, in complex control systems, while reducing theoverall time required to form a control system schematic, the time isstill appreciable.

Fourth, the process of generating diagnostic tools is also notstreamlined. For example, there may be specific conditions which shouldnot occur during a machining cycle. For instance, where the controlmechanisms for a clamp include both extended and retracted limitswitches, there should never be an instance when both the extended andretracted switches are triggered. Unlikely or unpredictable conditionsare referred to hereinafter as interesting conditions. In currentsystems, a control engineer should identify the most troublinginteresting conditions which should be identified during a machiningcycle and provide logic outputs to support indicators of the interestingconditions.

In addition, some systems require actual diagnostic functions to beperformed. For example, many times an interesting condition has only oneor two possible causes. In these cases, the system may be required to,when the interesting condition occurs, identify the possible causes sothat a system operator can locate the cause of the interesting conditionand eliminate the cause. Here, the system usually includes a screen forproviding an alphanumeric message to the operator.

Moreover, some applications may require a system to attempt to furtheridentify or even eliminate the cause of an interesting condition. Inthis case, when an interesting condition occurs, the system may checkother system I/O to further diagnose the cause of the condition,providing a report to the operator via a system screen. In thealternative, when an interesting condition occurs and there is only onepossible cause, the system may attempt to eliminate the condition. Forexample, where a transfer bar is stuck, the system may be programmed toreverse the transfer bar prior to moving forward again.

Where a system requires diagnostic functions in addition to interestingcondition reporting, in addition to identifying interesting conditions,the control engineer has to identify all possible causes of eachinteresting condition, compose informative instructions for display toan operator indicating the causes of the interesting conditions, providelogic to identify the interesting conditions and, in some cases, providelogic to eliminate the interesting conditions.

In addition to interesting conditions which should not occur, there mayalso be other interesting conditions which should be reported to asystem operator. In these cases diagnostic logic should be provided toidentify these other interesting conditions and provide some type ofindication. Clearly identifying all interesting conditions and theircauses, composing messages for each cause and providing logic to do thesame is a complex and time consuming endeavor.

Fifth, the process of specifying HMI design and logic required tosupport HMI representations is not streamlined. Here the controlengineer, while creating the control logic generally, has to weave HMIlogic into the system which provides desired PLC input signals (e.g.signals from sensors) and enables control via PLC output signals tocontrol actuators.

Sixth, the process of debugging is not streamlined. As indicated above,an entire mechanical line (including all tools and accompanying controlsystem) has to actually be designed and constructed and PLC executioncode has to be generated prior to performing the debugging process.Obviously, once tools have been constructed and execution code has beenprovided the process of backtracking to modify design is difficult andextremely costly.

Seventh, while the process described above may be manageable for asingle door frame assembly, similar processes are required for virtuallyevery separate part of a final product and similar processes are alsorequired to assemble parts into the final product. For example, becausea typical automobile requires many thousands of different parts, adevelopment process similar to the process described above must berepeated several thousand times to provide a completed automobile.

In the end, if line throughput is not sufficient parts of the line oreven the entire line may have to be modified to increase linethroughput. Once again, line modification is expensive as any systemchange can ripple through the entire control system thereby requiringadditional changes.

To streamline the debugging process and facilitate cost justificationprior to actually building and testing a manufacturing line, theindustry has attempted to debug an automated manufacturing linevirtually. In theory, virtual building and simulation enables a designerto modify line design relatively inexpensively when a bug is identifiedor when the costs associated with a particular line design cannot bejustified by an expected throughput.

One virtual simulation solution has been to effectively provide acartoon or movie illustrating all mechanical tools on a line in threedimensions and to run the manufacturing line in the virtual world toillustrate system operation. One way to accomplish this is to provide avideo module which includes a video clip for each separate mechanicaltool included on an assembly line. The video module is driven by themechanical timing diagram such that, when the timing diagram indicates aspecific resource movement, the video module plays the video clipassociated with the specific resource movement. The video module iscapable of running several video clips at a time on different sectionsof a display screen so that, by arranging the separate video clips onthe screen a general picture of a complete manufacturing process can beprovided. While this solution is helpful in visualizing a manufacturingprocess, unfortunately this solution does not illustrate tool control inthe real world which will result from actual execution code.

Another virtual simulation solution has been to provide off-lineprogramming for certain tools which is then linked to virtualrepresentations of those tools for simulating actual tool movements. Forexample, most robots are controlled by specialized controllers whichexecute controller specific languages (i.e. languages which typicallyare very different than the PLC language) in such a way that a robot canmove a work piece through space along a variety of path profiles. Somecompanies have developed virtual simulation tools which enable robotprograms which are developed off-line and in the controller specificlanguages to be used to drive virtual representations of the robot and awork piece handled thereby, including robot and work piece translationthrough virtual space. Importantly, the actual program used to drive therobot in the real world is used to drive the virtual robot in thevirtual environment. As described above, the components in the work cell(including the part or part components) already exist in some mechanicalCAD environment and are available to these programming tools. With thesesimulation tools a process engineer can interact with a virtual workcell and verify that his robot program does what he intends the programto do.

In order to truly debug the robot program in a virtual world, the restof the robot's real world environment must also be simulated such thatthe environment interacts dynamically with the robot motion. Forexample, clamps need to open and close, parts need to move into and outof the work cell, humans need to start and stop processes, sensors needto sense part and manufacturing tool locations and so on.

Unfortunately, while the simulation tools described above are used todrive virtual robots with the actual robot programs which will be usedin the real world, similar tools have not been developed for simulatingthe robot environment (e.g. clamps, sensors, actuators, stops andstarts, contingencies, HMIs, etc.). Existing tools simulate the robot'senvironment in the virtual world through a combination of proprietarymodeling languages and graphical interfaces which are whollydisconnected from the programs which are used to control themanufacturing tools in the real world. Thus, while the virtualenvironment is controlled via modeling languages, in the real worldthese non-robotic components are controlled via a PLC and a controllanguage (e.g. LL).

It should also be noted that, while robots themselves are internallycontrolled via controller specific languages, ultimately, each robot islinked to other system tools via a PLC which provides commands andreceives feedback via a more conventional control language.

To provide pre-construction cost justification, in addition to thevirtual simulation tools described above, various systems have beendeveloped for estimating both the costs associated with automatedmanufacturing lines and groups of related lines and the throughput forspecific lines. While these justification system may sometimesfortuitously generate cost data which is close to the actual cost datacorresponding to a completed system, in most cases these justificationsystems provide a ball park figure at best. Unfortunately, while a ballpark figure may be acceptable in some industries, in other industrieswhere competition is particularly keen, such ball park figures are notvery helpful in strategic financial planning as even a few percent errormay require line redesign.

Thus, it should be appreciated that despite industry efforts tostreamline the development process, the development process remainsextremely complex. The transition from part design to process design tomechanical design and then to controls is a paper activity. Each ofthese activities separately have their own software tools, and ofcourse, a competent set of engineers. The barriers between the softwaretools aren't just a matter of bridging different data types. Because thetools used in each phase of the development process evolved throughsolving their respective user's unique problems, their views of theworld are very different, even though they ultimately solve a commonproblem: how to build a product.

In addition to the system development problems discussed above, failureand interesting condition reporting diagnostics have a number ofshortcomings. One important shortcoming is that a system which supportsinteresting condition or failure reporting typically providesinsufficient information to enable a system operator to identify thecause of the failure. This is because system events may be contingentupon the conclusion of many other events and the diagnostics providedtypically cannot indicate which of a long string of contingent eventscauses a failure or an interesting condition to occur. For example,where extension of a clamp is to be monitored and failure reported, ifclamp extension is contingent upon 10 previous events, when clampfailure occurs and is reported, which of the 10 previous events failedis not reported and some investigation is required.

In addition, where prescriptive diagnostics are provided, theprescriptive messages (i.e., the text which indicates likely cause ofthe problem) are only pre-failure hunches as to what the actual cause offailure might be. While based on experience and hence correct much ofthe time, these hunches may not be correct and hence may lead anoperator in the wrong direction to address the failure this wastingsystem and operator resources.

For example, while the process engineer can specify specific tools andmovements required to carry out a process, the process information is ina form which, while providing specifying information to the controlengineer, cannot be used directly by control engineers to perform hisdevelopment tasks. Instead, each time the development process is handedfrom one engineer to another, the receiving engineer must start bygenerating his own set of information which is based on the informationspecified by the previous engineers and, only then can the receivingengineer begin to perform his task of specifying further information forthe next engineer down stream. Thus, the development process is brokenup into separate pieces despite the fact that common information threadspass through each of the separate phases of the development process.

For at least the aforementioned reasons, it would be advantageous tohave a system which would streamline the entire development processincluding defining an automated manufacturing line, developing executioncode to control the manufacturing line tools including tool movements,sequencing, emergency situations, etc., specifying and supporting HMIsfor the line, specifying diagnostics for the line, simulating lineoperation in a virtual environment prior to building the line and usingthe actual real world control programs to drive a virtual line in thevirtual environment, debugging the control programs, and providingschematic diagrams for a complete control system automatically. It wouldalso be advantageous to have a system wherein the common threads ofinformation which are provided by one engineer are sustained throughoutthe development process and automatically provided in a form which isuseable by engineers in subsequent process phases.

Moreover, it would be advantageous to have a diagnostics scheme whichcould specifically and immediately identify the symptoms which areassociated with a failure.

BRIEF SUMMARY OF THE INVENTION

It has been recognized that during the development process there arecertain common information threads which pass through variousdevelopment process phases. By studying the information passed from oneprocess phase to the next, inventive tools have been developed whichenable one engineer to use information in the form provided by previousengineers to continue the development process without reworking thereceived information. In this manner, the common threads of informationflow continuously through the development process from beginning to end.

It has further been recognized that the control engineering phase is acritical juncture for the common threads of information and, that byproviding suitable tools to the control engineer which organize thedevelopment information, the entire development process can bestreamlined and many advantages result. In effect, the inventive toolsoperate as a lynchpin which enables a control engineer to easilygenerate controls information from the process information (i.e.specified mechanical tools, behavior and sequencing) and which alsoenables controls information to be fed back and combined with theprocess information to virtually simulate a manufacturing process usingthe actual execution code which will be used in the real world.

To this end, among other things, the present invention includes a dataconstruct referred to generally as a “control assembly” (CA). It iscontemplated that a plurality of different CAS will be provided, aseparate CA for each type of mechanical resource which may be specifiedby a process engineer. Each CA includes several different informationtypes associated with the specific CA. For example, a CA for controllinga specific clamp may include: (1) specification of control mechanismsfor controlling the clamp; (2) a schematic diagram of the clampillustrating clamp control mechanisms and electrical and hydrauliclinks; (3) logic for controlling the control mechanisms used to in turncontrol the specific clamp; (4) diagnostic logic for indicating eithererroneous conditions which occur, other interesting conditions or statusof a process, (5) logic for supporting an HMI associated with the clamp;and (6) simulation specification for simulation purposes. Herein, theterm “logic” is used to refer to sequencing rules associated with thecontrol mechanisms corresponding to a specific CA.

As another example, a CA for controlling a robot may include: (1)specification mapping PLC I/O to robot I/O; (2) a schematic diagramreferencing the inputs and outputs and electrical and hydraulic links;(3) logic for interfacing to the robot; (4) diagnostic logic forindicating interesting conditions; (5) logic for supporting an HMIassociated with the robot; and (6) simulation specification forsimulation purposes. The CA is essentially an object in an objectoriented system for specifying information which a control engineer mustgenerate for an associated mechanical resource.

By observing the process information, including specified mechanicalresources, mechanical resource behavior and mechanical resourcesequencing, an engineer can divide the mechanical resources intoseparate mechanical blocks, each block assigned to a specific instanceof a CA. By including each mechanical resource in a mechanical block andassigning a CA for each mechanical block, control information is easilyspecified for each mechanical resource.

After all CAS have been specified, an inventive compiler is used tocompile all of the information in the CAS and to generate severaldifferent types of information. To this end, the compiler compiles theschematic diagrams of the separate control devices, linking the devicesaccording to a schematic rule set (SRS) to generate a complete schematicillustrating all line control devices, controllers and electrical andhydraulic links therebetween.

In addition, the compiler uses the logic from each of the CAS togenerate execution code for controlling and monitoring the entiremanufacturing line.

Moreover, the compiler compiles the HMI logic from each of the CAS intoHMI supporting code which enables a suitable HMI.

Furthermore, the compiler automatically compiles diagnostic informationfrom each of the CAS and generates diagnostic code which is interweavedwith the control code and which can be used to facilitate diagnosticfunctions during virtual testing and in real world operation.

In addition to the CA structure and the inventive compiler, theinvention further include a CA editor which enable a control engineer toeasily link to process information upstream thereby streamlining theprocesses of generating the controls information by carrying commonthreads of information from the process information into the controlsinformation. To this end, mechanical resources, their behavior and theirsequencing is displayed on a CA editor screen as a mechanical timingdiagram with mechanical resources and specific behaviors along avertical axis and behavior sequencing mapped along a horizontal timingaxis.

Using the CA editor, the control engineer identifies specific mechanicalresource types on the mechanical timing diagram and selects suitable CASfor controlling each of the mechanical resources or blocks of mechanicalresources which can be controlled by a single CA. As a CA is selected,the CA editor automatically creates an instance of the CA and places theCA in a control bar chart. The control bar chart includes CAS and CAbehavior along the vertical axis and sequencing of CA behavior along ahorizontal time axis. To distinguish between CA behavior and mechanicalresource behavior, CA behavior will be referred to hereinafter as CArequests.

In one embodiment, as CA requests are added to the timing diagram, therequests are sequenced in the same timing sequence as associatedmechanical resource behavior in the timing diagram. For example, if thefirst mechanical resource behavior in a process is to close a clampwithin a first period, the CA request to extend a piston (i.e. anactuator) to close the clamp is placed in the bar chart during the firstperiod. If the clamp behavior in the timing diagram is to open during atenth period, the CA request to retract the piston to open the clamp isplaced in the bar chart during the tenth period and so on.

After all CAS have been selected and the control bar chart is completelypopulated, the CA editor enables the control engineer to specifycontingencies at the edges of each request in the bar chart. In additionto the CA editor, the invention is meant to be used with an HMI editorand a diagnostics editor, each of which use CA information to configureand specify HMI and diagnostics features, respectively. After all of thesequencing information required to completely control the control systemhas been provided, an inventive compiler is used to generate executioncode as described above.

Moreover, the CA simulation specification can be used to provide atleast a subset of data which is required by a simulator for virtuallysimulating a process via video screens or the like. To this end, a coremodeling system (CMS) is a simulator which models all aspects ofmechanical resources supported by a system and which are simulatable.For example, when suitably programmed a CMS may model several differentmechanical resources including a clamp with position sensors. Clampoperation may have specific characteristics such as reversibility,average stroke speed, velocity limiting factors, a variable stroke speedcurve between start and stop, operating characteristics which change asa function of environmental characteristics (e.g. temperature, humidity,etc.) and so on. To model mechanical resources a CMS requires aplurality of data structures, a separate data structure for eachsimulatable resource in each instantiated CA. Unlike a one-to-oneI/O-function paring, advanced data structures reflect real worldresource behavior wherein request execution varies as a function of aplurality of different circumstantial characteristics.

A CMS which is equipped with separate data structures for eachsimulatable resource in each instantiated CA can operate as an interfacebetween a PLC and a movie module to receive PLC I/O combinations and,based thereon, cause the movie module to virtually simulate themechanical resources. The CMS also provides feedback to the PLC.Behavior characteristics such as simulation speed are simulated by theCMS controlling movie frame speed.

To facilitate data structure specification, the present inventioncontemplates that information required to form the structures portionthereof may be specified in CA simulation specifications and could beimported by the CMS for simulation purposes. While any sub-set ofsimulation information required by a CMS may be specified in a CAsimulation specification, there is a specific information sub-set whichis particularly easy to support and which makes sense to specify withina CA. To this end, the characteristics of a mechanical resource setassociated with a specific CA which affect resource operation can bedivided into two general categories or first and second simulationinformation sets including control characteristics and circumstantialcharacteristics.

On one hand, with respect to control characteristics, from a controlsperspective, a sub-set of resource characteristics are fundamental tothe specific resource and do not vary as a function of the circumstancesrelated to the resource (i.e., are universal for the specific resource).For example, many hardware vendor's provide clamps including controlmechanisms (e.g., valves, cylindicators, etc.) which, althoughconfigured using different hardware, perform the same general functionsin response to PLC I/O combinations. Thus, each clamp will attempt toextend when a PLC “extend” I/O combination is received and each clampwill attempt to retract when a PLC “retract” I/O combination is receivedand so on. In this case corresponding I/O-function is independent ofhardware configuration. Similarly, in this case, the I/O-functionpairings are independent of clamp environment including temperature,humidity, etc. (i.e., despite temperature and humidity, extension isattempted when a specific I/O combination is received). Thus, withrespect to similar clamps provided by different vendors, I/O-functionpairings are control characteristics which are universal for clampswhich would be used to perform the functions required by a specificresource.

On the other hand, circumstantial characteristics include all secondarycharacteristics which are not control characteristics and which affectrequest execution. For example, a first manufacturers clamp may have adifferent closing speed than a second manufacturers clamp. Similarly, afirst manufacturers clamp may close at different speeds depending upontemperature and humidity conditions or speed may vary as a function ofrecent clamp use (e.g., recent closing and opening may result in morerapid closure speed).

In a preferred embodiment the CA simulation specifications include onlycontrol characteristics and do not include circumstantialcharacteristics. The CMS preferably includes a database whereincircumstantial characteristics are stored which can be used to altersimulation events making simulation more realistic. The circumstantialcharacteristics are stored in simulation data structure templates (DSTs)and, upon export of the CA simulation specification, the controlcharacteristics and circumstantial characteristics are combined topopulate data structure fields required for simulation. Thereafter theCMS receives controller output signals and based on those outputsignals, modeling algorithms within the data structure and other datastructure information, causes realistic simulation.

In this manner the CA simulation specification is made relativelygeneral and the CMS facilitates modification of circumstantialcharacteristics without recompiling CAS. After a data structure ispopulated, circumstantial characteristics may be modified using a CMSinterface to reflect various environmental or resource characteristicsand simulation will also reflect such changes to facilitate realisticsimulation.

In addition to facilitating circumstantial characteristic modifications,by including only control characteristics in the CA simulationspecifications the number of CAS required to support design choices isminimized. In effect circumstantial parameterization is accomplished viathe CMS instead of via the CA.

Moreover, dividing characteristics between control and circumstantialcharacteristics and including control characteristics in the CAS makessense as the control characteristics can typically be gleaned from otherCA information which is specified for other than simulation purposes.For example, where a CA may support anywhere between one and four clampsand a user specifies that a CA will support only two clamps such that acompiler will provide execution code for controlling two clamps, clearlythis parameterization will be reflected in simulation such that, duringsimulation, only two clamp animations are generated. Thus, supported CAdevices are specified for control purposes and such specification isalso useful for simulation purposes. In effect, the effort required tospecify two clamps for execution code purposes can be exploited a secondtime for generating control characteristics required for simulation.While this example is relatively simple, it should be appreciated that ahuge amount of specification required for execution code purposes isexploited in this double-duty fashion thereby appreciably streamliningan otherwise daunting simulation specification process.

In another embodiment, the data required to populate essentially anentire data structure including both control and circumstantialcharacteristics may be specified within each CA simulationspecification. In this case, upon compiling, sub-sets of the requiredsimulation information for each simulatable resource are gleaned fromeach parameterized CA and are used to populate the data structures.After compiling, the data structure are imported by the CMS and thenused for interfacing purposes. Other simulation specificationembodiments may include other sub-sets of control and circumstantialcharacteristics.

In a simplified embodiment of the invention where a one-to-one pairingof PLC I/O and virtual simulation is supported without circumstantialcharacteristics, the parameterization simulation specification maysimply be a PLC I/O mapping table which maps PLC I/O combinations tospecific video clips. In this case, after the parameterizedspecification is compiled, the specification is imported by the CMS andused for interfacing purposes.

The inventive address mapper facilitates mapping of PLC I/O to virtualmechanical resources to cause virtual simulation, identifies mechanicalresource conditions (e.g. position, temperature, etc.) which are to besensed during real world operation and provides inputs to the PLCindicating identified conditions during virtual processing.

In addition to control and circumstantial characteristics, a third typeof character referred to as a third entity characteristic iscontemplated. Third entity characteristics include characteristics ofentities other than mechanical resources which interact with the PLC orwhich only minimally interact with the PLC and which must be modeled tofacilitate realistic simulation. For example, third entities includesystem operators, a shot pin used to lock two devices together, anE-stop and corresponding hardware and so on.

Thus, the invention provides a system which streamlines the entiredevelopment process including defining an automated manufacturing line,developing programs to control the manufacturing mechanical resourcesincluding resource movements, sequencing, emergency situations, etc.,specifying and supporting HMIs for the line, simulating line operationin a virtual environment prior to building the line and using the actualreal world execution code to drive a virtual line in the virtualenvironment, debugging the control programs, and automatically providingschematic diagrams for a complete control system.

In addition to the inventive aspects described above, in another aspectthe invention includes status based diagnostics wherein every eventwhich is to occur during a process is monitored and, when an expectedevent fails to occur, the failed event is reported. For example, where aclamp extension request is contingent upon the occurrence of tenprevious events, when one of the previous events fails, status baseddiagnostics reports the failed event. In this manner, when a failureoccurs, the specific symptoms of the failure are immediately reportedand the operator can then surmise the cause of the failure quickly.

Request events are represented in the CAS and therefore status baseddiagnostics can easily be provided in each CA to minimize the task ofprogramming diagnostics code for each event in a process. For example,where a clamp CA includes extend and retract requests and ten separateevents, diagnostics can be provided once for each event in a template CAand, therefore, as CA instances are instantiated (i.e. selected by anoperator for control purposes), the status based diagnostics areproliferated throughout the control process. In this manner, the task ofproviding status based diagnostics which seemed virtually impossiblebefore can easily be accomplished through CA duplication (i.e.,instantiation).

These and other objects, advantages and aspects of the invention willbecome apparent from the following description. In the description,reference is made to the accompanying drawings which form a part hereof,and in which there is shown a preferred embodiment of the invention.Such embodiment does not necessarily represent the full scope of theinvention and reference is made therefor, to the claims herein forinterpreting the scope of the invention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1A is a block schematic diagram of a computer system for example, apersonal computer system in accordance with a preferred embodiment;

FIG. 1B provides a display of ladder logic in accordance with apreferred embodiment;

FIG. 2 illustrates an enterprise control system in accordance with apreferred embodiment;

FIG. 3 illustrates a CA display from an enterprise control database inaccordance with a preferred embodiment;

FIG. 4 is a block diagram depicting the logical flow of the enterprisecontrol system in accordance with a preferred embodiment;

FIG. 5A is a block diagram schematic representing a system including adiagnostic engine for diagnosing the behavior of a machine controlled bya discrete event control system in accordance with a preferredembodiment of the present invention;

FIG. 5B is a flow chart representing exemplary steps for defining,updating and selecting the optimum diagnostic rules for the system ofFIG. 5a while the diagnostic engine is in the learning mode;

FIG. 5C is a flow chart representing exemplary steps for identifying amalfunction in the behavior of the machine and updating the timingstatistics associated with the diagnostic rules while the diagnosticengine of FIG. 5a is in the diagnostic mode;

FIG. 6 illustrates the user display for opening a project in accordancewith a preferred embodiment;

FIG. 7 is a Designer Studio window in accordance with a preferredembodiment;

FIG. 8 is a Designer Studio display with CAS completed in accordancewith a preferred embodiment;

FIG. 9 is a CA wizard in accordance with a preferred embodiment;

FIG. 10 is a CA wizard name operation in accordance with a preferredembodiment;

FIG. 11 is a CA wizard to select control resources in accordance with apreferred embodiment;

FIG. 12 is a CA wizard to label components associated with the CA inaccordance with a preferred embodiment;

FIG. 13 is a CA wizard summary in accordance with a preferredembodiment;

FIG. 14 is a Designer Studio display of a new CA integration inaccordance with a preferred embodiment; and

FIG. 15 is a schematic of a pneumatic system of a control environment inaccordance with a preferred embodiment;

FIG. 16 illustrates the hierarchical relationship between a machine andan indexer in accordance with a preferred embodiment;

FIG. 17 illustrates a template in accordance with a preferredembodiment;

FIG. 18 illustrates a machine tree in accordance with a preferredembodiment;

FIG. 19 illustrates a master control panel in accordance with apreferred embodiment;

FIG. 20 illustrates the symbolic expression language in accordance witha preferred embodiment;

FIG. 21 illustrates an exemplary rung in accordance with a preferredembodiment;

FIG. 22 illustrates a required full set of conditions in accordance witha preferred embodiment;

FIGS. 23-35 illustrate an exemplary set of templates in accordance witha preferred embodiment;

FIG. 36 is a flow chart of the process by which the user creates thecontrol diagram in accordance with a preferred embodiment;

FIGS. 37-43, represent all of the templates required to completelyspecify an axis in accordance with a preferred embodiment;

FIG. 44 illustrates a control panel editor in accordance with apreferred embodiment;

FIGS. 45 & 46 illustrate bar chart images in accordance with a preferredembodiment;

FIG. 47 is a contingency screen in accordance with a preferredembodiment;

FIG. 48 is a flowchart detailing the logic associated with compilationin accordance with a preferred embodiment;

FIGS. 49A and 49B are ladder logic displays in accordance with apreferred embodiment;

FIG. 50 illustrates an attributes table in accordance with a preferredembodiment;

FIG. 51 is a ladder logic display in accordance with a preferredembodiment;

FIG. 52 is a flowchart of observed functional processing in accordancewith a preferred embodiment;

FIG. 53 is a flowchart of bucket processing in accordance with apreferred embodiment;

FIG. 54 is a splash screen in accordance with a preferred embodiment;

FIG. 55 is the initial display for the Designer Studio in accordancewith a preferred embodiment;

FIG. 56 illustrates a menu that is utilized to open a project inaccordance with a preferred embodiment;

FIG. 57 illustrates a display menu that is utilized to select anexisting project to load in accordance with a preferred embodiment;

FIG. 58 illustrates an Open Project dialog in accordance with apreferred embodiment;

FIG. 59 illustrates a menu display for facilitating an “Add CA” dialog5900 in accordance with a preferred embodiment;

FIG. 60 illustrates the first menu in an “Add CA” dialog in accordancewith a preferred embodiment;

FIGS. 61 to 67 illustrate a user experience with a wizard in accordancewith a preferred embodiment; and

FIG. 68 illustrates the processing that occurs when a user presses thefinish button in accordance with a preferred embodiment;

FIG. 69 illustrates the selection processing associated with aparticular CA in accordance with a preferred embodiment;

FIG. 70 illustrates the processing of a CA in accordance with apreferred embodiment;

FIGS. 71 to 79 provide additional displays in accordance with apreferred embodiment;

FIG. 80 is a block diagram of a CA in accordance with a preferredembodiment;

FIG. 81 is a schematic representation of an exemplary control device forcontrolling a cylindicator control mechanism;

FIG. 82 is similar to FIG. 81, albeit for a two position valve controlmechanism;

FIG. 83 is similar to FIG. 81, albeit for a spring return valve controlmechanism;

FIG. 84 is a schematic illustrating the various sections of an exemplarycontrol assembly;

FIG. 85 is a schematic diagram illustrating an exemplary logicspecification of FIG. 84;

FIG. 86 is a schematic illustrating an exemplary HMI specification ofFIG. 84;

FIG. 87 is a schematic illustrating an exemplary diagnosticsspecification of FIG. 84;

FIG. 87A is a schematic illustrating an exemplary status baseddiagnostics specifications;

FIG. 88 is a schematic illustrating an exemplary simulationspecification of FIG. 84;

FIG. 89 is an exemplary control bar chart used to sequence controlassemblies according to the present invention;

FIG. 90 is a block diagram illustrating various components of a systemused to practice the present invention;

FIG. 91 is an exemplary mechanical resource timing diagram;

FIG. 92 is a schematic illustrating an exemplary resource editor windowaccording to the present invention;

FIG. 93 is similar to FIG. 92, albeit illustrating a second editorwindow;

FIG. 94 is similar to FIG. 92, albeit illustrating yet another editorwindow;

FIG. 95 is a schematic illustrating an exemplary HMI screen;

FIG. 96 is a schematic similar to FIG. 92, albeit illustrating yetanother editor window;

FIG. 97 is a schematic diagram illustrating an HMI editor screenaccording to the present invention;

FIG. 98 is a schematic illustrating an HMI editor screen for selectingmonitorable and controllable I/O;

FIG. 99 is a schematic illustrating a diagnostics editor screen;

FIG. 100 is a schematic diagram illustrating a diagnostics editor screenfor selecting diagnostics to be supported by a control system;

FIG. 101 is a schematic diagram of the PLC of FIG. 90;

FIG. 102 is a schematic diagram illustrating an exemplary PLC I/O table;

FIG. 103 is a schematic diagram illustrating an exemplary HMI linkingtable;

FIG. 104 is a schematic diagram illustrating an exemplary diagnosticslinking table;

FIG. 105 is a schematic diagram illustrating the compiler of FIG. 90;

FIG. 106 is a schematic diagram illustrating an exemplary code buildingtable;

FIG. 107 is a schematic diagram illustrating the exemplary PLC I/O tablesegment of FIG. 106;

FIG. 108 is a schematic diagram similar to FIG. 107 albeit illustratinga different table segment;

FIG. 109 is a block diagram illustrating an exemplary code and PLC I/Ocompilation method according to the present invention;

FIG. 110 is an exemplary HMI building table;

FIG. 111 is a schematic diagram of a exemplary diagnostics buildingtable;

FIG. 112 is a block diagram of an exemplary method for compiling and HMIlinking table and a diagnostics linking table;

FIG. 113 is a schematic diagram of an exemplary schematic buildingtable;

FIG. 114 is a block diagram of an inventive method for compiling aschematic diagram according to the present invention;

FIG. 115 is a schematic diagram of an exemplary simulation buildingtable;

FIG. 116 is a block diagram of a inventive simulation table compilingprocess;

FIG. 117 is a schematic diagram of the core modeling system of FIG. 90;

FIG. 118 is a schematic diagram of one of the data structures of FIG.117;

FIG. 119 is a flow chart illustrating an inventive method for combiningcontrol characteristics from simulation specifications andcircumstantial characteristics to provide instantiated data structureinstances;

FIG. 120 is a flow chart illustrating an exemplary simulation methodusing the data structures of FIG. 117; and

FIG. 121 is a schematic diagram of a third entity data structureaccording to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

I. Newly Added Specification

While it is contemplated that the inventive editors and database may beimplemented in any of several different computer technologies,preferably, the editors are implemented using universal technologiessuch as JAVA by Sun Microsystems or ActiveX by Microsoft. Also, while itis contemplated that the PLC logic may be implemented in any of severaldifferent computer languages, because most PLCs run relay ladder logic(LL) programs, it is preferred that the PLC logic be in the LL languageand is described as such hereinafter.

Unless indicated otherwise, identical numbers and legends on differentFigures are used to refer to identical system components, signals,constructs and so on.

While the invention includes various interfaces and editors for enablinga system user to specify logic, initially an industrial controlsparadigm will be explained which serves as a foundation for theinventive editors, compiler and simulator. This paradigm will make allof the aspects of the present invention more easily understandable.After the industrial controls paradigm is described, a CA editor, an HMIeditor and a diagnostics editor are described which use the controlsparadigm to specify controls logic. Next, the inventive compiler isdescribed followed by the inventive simulator which uses compiler outputto drive a virtual machine line using real world execution code.

A. Industrial Control Paradigm

When performing the controls engineering tasks, a control engineer hasto provide many different types of controls information including, amongother types: (1) control mechanism specification; (2) logic or executioncode to control the control mechanisms; (3) logic or execution code tosupport diagnostic requirements; (4) logic or execution code to supportHMIs; (5) schematic electrical and hydraulic diagrams and so on.Hereinafter, all of the controls information provided at the end of acontrol engineering process will be referred to generally as “controlproducts.”

It has been recognized that system control can be divided into ahierarchy of separate control levels, each level including similarcontrol concepts and each higher level including instances of controlconcepts from the immediately lower level. It has also been recognizedthat each of the separate control levels lends itself uniquely tospecifying one or more types or sub-types of the control informationwhich must be specified during the control engineering process.

The hierarchy consists primarily of four separate control levels whichcan be used together to specify, virtually construct, simulate and debuga control system for any mechanical process including any type ofmechanical resource. The four levels include what will be referred tohereinafter as factory floor input and output signals (i.e. the I/Olevel), control devices, control assemblies and control sequencing.

1. Factory Floor I/O

As a general rule, a mechanical resource itself is simply a tool which,although capable of certain movements, cannot cause a movement to occur.To cause mechanical resource movement, one or more control mechanismshave to be linked to the mechanical resource. For example, in the caseof a clamp which includes a clamping surface (i.e. the surface whichmoves toward an opposite surface to close), the control mechanisms mayinclude a cylinder and a two position valve wherein a cylinder piston islinked to the clamp surface and the valve includes both extend andretract solenoids which can be controlled to extend or close the clampsurface or to retract or open the surface, respectively. When the extendsolenoid is excited, an armature linked thereto allows high pressure airto force the piston and clamp surface into the extended position. Whenthe retract solenoid is excited, the armature allows air to force thepiston and clamp surface into the retracted position. Thus, in thiscase, two control mechanisms, the cylinder and the valve, are requiredto move the clamp between the open and closed positions.

Similarly, as a general rule mechanical resources themselves do notgenerate signals which can be used to determine mechanical resourceposition for monitoring purposes. Instead, specific control mechanismshave to be provided to facilitate monitoring. To this end, in the caseof the clamp above, where it is important to confirm clamp positionduring a process, the cylinder may be equipped with proximity sensorsfor sensing the position of the cylinder piston to ensure that thepiston is in the retracted and extended positions when required by theprocess.

To control or manage control mechanisms, control output signals areprovided by a PLC to the control mechanisms and, the PLC receives inputsignals from the control mechanisms indicating current control mechanismand mechanical resource status. For example, an exemplary valve solenoidincludes a “hot” terminal and a “common” terminal. To excite a solenoid,for safety purposes it is customary to require that each of the hot andcommon terminals be excited. Thus, for a two position valve includingtwo solenoids, a PLC must provide four output signals, one hot and onecommon terminal signal for each of the two separate solenoids. For a twosensor cylindicator (i.e. a cylinder with proximity sensors for thepiston inside), no PLC outputs are required but the cylindicatorprovides two input signals, one indicating an extended piston and theother indicating a retracted piston.

Thus, from the perspective of a control engineer, each of the controlmechanisms has the appearance of a proverbial “black box” havingspecific inputs (i.e. feedback inputs to the PLC) and outputs (ControlSignals from the PLC). Control mechanism I/O constitute the factoryfloor inputs and outputs which make up the lowest or I/O controls level.

2. The Control Device (Signal Container)

In addition to input and output signals, other control information canbe specified for each of the control mechanisms. For instance, given aspecific structure, each control mechanism also has specific “normal” orexpected states and specific “failure” or unexpected states. Forexample, for the cylindicator described above, a failure state occurswhen both the extended and retracted proximity sensors generate signals(i.e. indicate piston proximity). All other combinations of cylindicatorinputs are normal (i.e. both sensors indicating negative or one sensornegative while the other is positive).

Moreover, for each failure state the control information may include aspecified activity (e.g. reporting the failure state). For example,where two cylindicator sensors simultaneously indicate proximity of thepiston, the activity may include generating a text message forindicating mechanism failure such as “Cylindicator Sensor Failure”.

Furthermore, given a specific structure, each control mechanism can berepresented by a standard schematic symbol preferably similar to thesymbols used in the industry to represent the specific control mechanismand including connection points for different energy transferring media(e.g. electrical, pneumatic and hydraulic inputs and outputs, water,mechanical linkages, etc.). In this regard part information relating tothe specific control mechanism may be included with the schematicsymbol.

According to the present invention, all of the control informationassociated with each control mechanism is encapsulated in a single dataconstruct referred to herein as a “control device” (CD). An exemplarycontrol device includes a device name, a logic section, a schematicsection and a diagnostics section. While the exemplary CD's include eachof logic, schematic and diagnostics sections, other less complete CD'sare contemplated. For example, a CD may not include a schematic section,a diagnostics section or a logic section.

Three separate examples of control devices are provided hereinafter toillustrate some of the concepts described above. The three examplesinclude a cylindicator (see FIG. 81), a two-position valve (see FIG. 82)and a spring return valve (see FIG. 83). It should be understood thatthe three exemplary control devices described herein are not meant to beexhaustive and that many other control devices are contemplated by thepresent invention.

In addition to representing real control mechanisms a control device mayalso represent a “virtual” device such as a robot controller whichreceives and provides inputs and outputs, respectively, from a PLC toenable control and feedback.

Thus, control devices have both a logic aspect which defines inputs andoutputs to and from a controller and a hardware aspect which specifiesparts, manufacturers, properties and so on.

Despite the fact that many control devices include more than just agrouping of input and output signals and that other CD's may not includeI/O groupings, it is helpful to think of an exemplary control device asa signal container including all of the input signals provided by acontrol mechanism to a PLC and all of the output signals provided to thecontrol mechanism by the PLC.

a. Cylindicator

Referring to FIG. 81, a cylindicator control device 8500 includes adevice name 8502, a logic section 8504, a schematic section 8506 and adiagnostic section 8508. The device name 8502 is chosen such that thename will be recognized by an exemplary control engineer and will beassociated with a corresponding control mechanism. Thus, in the presentexample, the control device 8500 in FIG. 81 is named “cylindicator withtwo sensors” and corresponds to a cylindicator with two proximitysensors as described above.

Hereinafter, when describing logic in the context of I/O, I/O generatingcomponents will be said to be active or excited on one hand or passiveon the other hand meaning that the components are either providingenergized and providing a true signal on one hand or passive andproviding a negative signal, respectively. In the context of a LL coil,an excited coil is associated with a true signal and a coil which is notexcited is associated with a false signal. In the context of a LLcontact, a closed contact is associated with a true signal and an opencontext is associated with a false signal. In addition, in I/O tables,condition tables and bar charts which follow, cross hatched boxesindicate active or excited I/O and clear boxes indicate passive I/O.

Logic section 8504 includes an I/O table 8510, a normal conditions table8512 and a failure conditions table 8514. I/O table 8510 indicatessub-mechanisms of each control mechanism which are actually linked tospecific I/O. Thus, the cylindicator includes both the extendedproximity sensor 8516 and the retracted proximity sensor 8518 andindicates PLC inputs 8520, 8522 which are provided by sensors 8516 ad8518, respectively. In the case of a cylindicator there are no outputs(i.e. terminals which receive control signals from a PLC) and thereforenone are listed.

Normal conditions table 8512 indicates all possible normal combinationsof inputs 8520 and 8522. To this end, table 8512 indicates that when thecylindicator is extended, the extend sensor 8516 generates a positivesignal indicating piston proximity and the retract sensor 8518 isnegative, when the cylindicator is retracted, the retract sensor 8518generates a positive signal indicating piston proximity and the extendsensor 8516 is negative and when the cylindicator is between theextended and retracted positions, both of the sensors 8516 and 8518 arenegative or passive.

The failure table 8514 indicates all possible failure combinations ofinputs 8520 and 8522. To this end, the only possible failure combinationis when each of sensors 8516 and 8518 generate positive signalsindicating piston proximity (i.e. it is impossible for a piston to besimultaneously extended and retracted).

Referring still to FIG. 81, schematic section 8506 includes a schematicdiagram 8507 of the control mechanism associated with control device8500. In this case, the schematic 8528 is of a cylindicator with twosensors and includes connector nodes. Although not illustrated, otherpart information may be provided with the schematic (e.g. cost, specificmechanical requirements, etc.) The diagnostics section 8508 includesinformation indicating rules for identifying I/O conditions which are“interesting conditions” from a diagnostics perspective and indicatingactivities which should be performed when an interesting condition isidentified. To this end, section 8508 includes a diagnostics table 8509including I/O requirements 8511 and corresponding activities 8513wherein each I/O requirement 8511 identifies a specific set ofinteresting conditions (i.e. I/O) and the activity 8513 indicates theactivity to be performed when a corresponding I/O requirement occurs. Inthe case of a cylindicator an interesting condition occurs when bothextended and retracted proximity sensors 8516 and 8618 generate activeinput signals indicating the failure condition 8514. In table 8509“failure” 8515 is listed as one requirement or interesting condition.The activity associated with failure 8515 is to generate an alphanumerictext phrase “cylindicator sensor failure” 8517.

Other interesting conditions may include normal condition sets which,for some reason (e.g. their order within a sequence), render the normalset diagnostically useful. For example, if a particular sequence is notobservable in the real world but is important from a diagnosticsperspective, it may be advantageous to provide the end condition set ofthe sequence as a requirement in table 8509 and include some type ofindicating activity in activities column 8513.

Other activities, in addition to reporting, may also include diagnosticsbased on prior experience. For example, the text message specified inthe activity may indicate the likely cause(s) of the interestingcondition. Moreover, the text message may also specify a prescription toeliminate the diagnosed cause.

Furthermore, the diagnostic activity 8513 may also be proactive indiagnosing the cause of an interesting condition. To this end, theactivity 8513 may specify additional I/O to be checked if a specificinteresting condition occurs and, based on the additional I/O, theactivity 8513 may select from a list of other diagnostic activity.

Moreover, the diagnostic activity 8513 may be proactive in eliminatingan interesting condition. To this end, the activity 8513 may specifyoutput signals which should be modified when a particular interestingcondition occurs. For example, in FIG. 81, when a failure condition(e.g. 8514) occurs, in addition providing a text phrase, the activity8513 may also modify output signals to clamp valves to open the clamps.

In any of these diagnostic cases, the requirements 8511 include asub-set of specific I/O conditions of the control mechanism and theactivities include outputs. The diagnostic outputs are, in the case of atext phrase or other indication, to an HMI and, in the case of proactivediagnostics or I/O modification, to one or more control mechanisms.

b. Two-Position Valve

Referring to FIG. 82, a two-position valve control device 8600 includesa device name 8602, a logic section 8604, a schematic section 8606 and adiagnostic section 8608. The device name 8602 is “two-position valve.”The logic section includes an I/O table 8610 and a normal conditionstable 8612. I/O table 8610 indicates sub-mechanisms of each controlmechanism which are actually linked to specific inputs and outputs.Thus, table 8610 lists both the valve's extend solenoid 8616 and retractsolenoid 8618 and indicates the PLC outputs provided for each of the twosolenoids (i.e. outputs 8620 and 8622 to solenoid 8616 and outputs 8621and 8623 to solenoid 8618. In the case of a two position valve there areno inputs (i.e. PLC feedback signals) and therefore none are listed.

Normal conditions table 8612 indicates all possible normal combinationsof outputs 8620 through 8623. To this end, table 8612 indicates thatwhen the outputs to solenoid 8616 are active, the outputs to solenoid8618 must be passive and vice versa.

Note that there is no failure conditions table for the two-positionvalve despite the fact that a failure condition could occur. Forexample, all four outputs 8620 through 8623 could be active. While afailure table could be provided, providing a failure table is a matterof control device designer choice and may depend on the likelihood of afailure occurring, the importance of such a failure occurring and whichpart of a control system likely causes a failure. For example, in thecase of a valve having no inputs and one or more outputs, any failure inoutputs would likely be caused by the PLC itself and thus the PLC, notthe device being controlled thereby, should determine failure.

The schematic section 8606 includes a schematic diagram 8628 of a twoposition valve including connector nodes.

The diagnostics section 8708 includes diagnostics table 8604 havingrequirement and activity columns 8611 and 8613, respectively. In thiscase, because there are no failure conditions specified for the twoposition valve, no failure diagnostics are provided. However, theexample herein includes diagnostics for another “interesting condition.”In this case, the interesting condition is when the extend solenoid hotand common outputs are both excited and the retract solenoid hot andcommon outputs are both passive. This condition corresponds to an extendrequest and extend requirement 8615. When the extend requirement 8615 ismet, the prescribed activity 8617 provides a text message “ExtendRequested” to an HMI for display.

Although a requirement and an activity are listed in table 8609 forexemplary purposes, hereinafter, to simplify this explanation, it willbe assumed that diagnosis table 8609 is empty.

c. Spring Return Valve

A spring return valve is a valve which includes a single solenoid, anarmature and a spring. The solenoid, like other solenoids describedabove, includes both a hot terminal and a common terminal, each of whichhave to be excited to activate the solenoid. The armature is linked tothe solenoid and, when the solenoid is activated, the armature isextended against the force of the spring. When solenoid power is cutoff, the spring forces the armature and solenoid back to a steady stateposition.

Referring to FIG. 83, a spring return valve control device 8700 includesa device name 8702, a logic section 8704, a schematic section 8706 and adiagnostic section 8708. The device name 8702 is “spring return valve.”The logic section includes an I/O table 8710 and a normal conditionstable 8712. I/O table 8710 indicates sub-mechanisms of the controlmechanism which are linked to specific inputs and outputs. Thus, table8710 lists the valve's extend solenoid 8716 and indicates the PLCoutputs provided to the extend solenoid (i.e. outputs 8720 and 8722). Inthe case of a spring return valve there are no inputs (i.e. feedbacksignals to the PLC) and therefore none are listed.

Normal conditions table 8712 indicates all possible normal combinationsof outputs 8720 and 8722. To this end, table 8712 indicates that theoutputs to solenoid 8716 have to either be both active or both passive.As with the two-position valve there is no failure conditions table forthe spring return valve. The schematic section 8706 includes a schematicdiagram 8728 of a spring return valve including connection nodes.

The diagnostics section 8708 includes a diagnostics table 8709 includinga requirement column and an activity column 8711, 8713, respectively. Inthis case, because there are no failure conditions specified for thespring return valve, no failure diagnostics are provided. Moreover, noother interesting conditions are specified and therefore table 8709 isleft blank.

Thus, a control device is a database construct which includes, but isnot limited to, all of the control information about a control mechanismwhich would be specified during the control engineering phase of adevelopment process. In addition, as will be understood shortly, thecontrol device is a building block from which control assemblies areformed.

3. The Control Assembly (Control Device Container)

Like the control device, a control assembly (CA) according to thepresent invention is a data construct which includes controlinformation. However, while a control device includes essentially all ofthe information which a control engineer specifies with respect to aspecific control mechanism (e.g. a cylindicator, a valve, etc.), the CAconfiguration has been designed to include essentially all of theinformation which a control engineer specifies with respect to aspecific mechanical resource (e.g. a clamp, a robot, etc.) or, in somecases, with respect to a group of mechanical resources (e.g. a pluralityof clamps which are synchronous). To this end an exemplary CA operatesproverbially as a “device container” for all of the control deviceswhich operate together to control a mechanical resource.

The invention contemplates a plurality of different CAS. For example, aprocess engineer may have the choice to select any of three differentmechanical clamps for clamping a work item in place along a transferline wherein each of the three clamps requires different controlmechanisms to control the clamp.

A first clamp type may require only two control mechanisms including onetwo-position control valve and a cylinder. The second clamp type mayalso require only two control devices but the required devices may bedifferent than those required for the first clamp type. For example, thesecond clamp type may require a two position valve and a cylinderincluding two proximity sensors (i.e. a cylindicator). The third clamptype, like the second, may require a two-position valve and acylindicator and, in addition, may also require a redundant springreturn valve. In this case, the spring return valve is positionedbetween the two position valve and the cylinder. When the spring returnsolenoid is excited, the spring armature extends against the force ofthe spring and allows high pressure air to force the piston and clampsurface into the closed and extended position and, when solenoid poweris cut off, the spring forces the valve into the retracted positionallowing the air to force the piston and clamp surface into the open andretracted position. The spring return valve causes the clamp to open ifpower is cut off from the solenoids.

In this case, a CA library would include three separate clamp CAS, aseparate CA for each of the possible clamp types. The information in oneCA all corresponds to a single mechanical resource and the controldevices within the CA which are required to control the mechanicalresource. For instance, in the clamp example above, the CA correspondingto the third clamp type would include only information corresponding toa two-position valve, a spring return valve and a cylindicator.

In addition to the three CAS described above, the invention contemplatesa CA library including many more CAS, each CA corresponding to adifferent set of control devices used to control a specific mechanicalresource. For example, there may be ten different CAS corresponding toten different robot configurations (i.e. mechanical resources), theremay be three CAS corresponding to three different pin locatorconfigurations, there may be eight CAS corresponding to eight differentslide configurations and so on. a. Exemplary CA Structure In theinterest of simplifying this explanation and an explanation of thecontrol paradigm on which the invention rests, an exemplary CA will bedescribed which is specifically designed to include control informationfor the third clamp type above (i.e. a CA including a two-positionvalve, a spring return valve and at least one cylindicator). It will beassumed that the exemplary CA can be used to specify control informationfor anywhere between one and four separate clamps for each CA instance.To this end, it has been recognized that certain control assemblies andcorresponding control mechanisms may be capable of controlling more thana single mechanical resource. For example, if air pressure generated byan air source is high enough, air pressure passing through a singlevalve has enough force to simultaneously move two or more clamps. Tominimize system costs, a single valve design, or any design whichreduces the number of control mechanisms, is advantageous. While asingle valve may be required to move a plurality of clamps, each clamprequires a dedicated cylindicator. Thus, the exemplary CA includescontrol devices for controlling up to four cylindicator.

In a preferred embodiment a CA is divided into information fields orspecifications, a separate specification for each one of the differenttypes of control information. For example, referring to FIG. 84, anexemplary CA 9000 may include, among other information specifications,five control information specifications including (1) logicspecification 9002; (2) schematics specification 9004; (3) HMIspecification 9006; (4) diagnostic specification 9008; and (5)simulation specification 9300.

In addition, the CA is also provided with a template type indicator9001. As with the control device names, type indicators 9001 are chosento reflect the nature of the CA type so that the content of the CAtemplate can be understood by a control engineer essentially from the CAtemplate type identifier 9001. In the present example the type indicator9001 is “SafeBulkHeadClampSet” indicating that the template type is forcontrolling a clamp and defines a redundant spring return valve forsafety purposes.

In a preferred embodiment of the invention, the CA template includes allcontrols information required for a specific mechanical resource andwhich can be used over and over again to specify the information inseparate template instances. When a template is accessed for use, thespecific template use is referred to as an instance of the CA and theact of using the template is referred to as instantiating an instance ofthe CA. When a CA is instantiated, the specific CA instance is given aunique name which is then used thereafter to reference the specific CAinstance and to identify control system parameters corresponding to theinstance. For example, where two identical clamp CAS are required tocontrol different clamps, the first CA instance may be provided the name“1stclamps” and the second CA instance may be provided the name “2ndclamps”. Hereinafter, the exemplary CA 9000 described will be referredto by the name 1stclamps 9003.

Hereinafter, each of the CA specifications is described separately.Initially, each of the exemplary specifications would be generic in thesense that the specification would not be parameterized to reflectencapsulated information about a specific CA instance. The describedspecifications, however, reflect CA instance parameterized as will beexplained in more detail below.

i. Logic Specification

Referring to FIGS. 84 and 85, logic specification 9002 includes I/Otables corresponding to each of the control devices which may possiblybe included in the CA. Thus, for a CA including a two-position valve9421, a spring return valve 9423 and capable of supporting fourcylindicators 9425, 9427, 9429 and 9431 (i.e. one cylindicator for eachcontrollable clamp), logic specification 9002 includes I/O tables 8510a, 8510 b, 8510 c, 8510 d, 8610 and 8710 (see also FIGS. 81-83). For thepurpose of this explanation the two-position valve 9421 outputs arereferred to as 01, 02, 03 and 04, the spring return valve 9423 outputsare referred to as 05 and 06 and the cylindicator inputs are referred toas 11 through 18. In addition, logic specification 9002 also includesI/O request charts including an extend request chart 9030 and a retractrequest chart 9032 corresponding to extend and retract requests 9031,9033, respectively.

Extend chart 9030 includes a sequence section 9034 and a propertiessection 9036. Properties Section 9036 is explained below. Sequencesection 9034 includes a bar chart 9038 including a separate bar for eachof the inputs and outputs in the I/O tables 8510 a, 8510 b, 8510 c, 8510d, 8610 and 8710. Thus, bar chart 9038 includes bars 9040 through 9043corresponding to I/O table 8610, bars 9044 and 9045 corresponding to I/Otable 8710 and bars 9046 and 9047 corresponding to I/O table 8510 and soon. Note that chart 9038 is separated into six sections corresponding totables 8610 and 8710 for illustrative purposes only and would morelikely appear as a single table.

The extend clamp request begins at the left edge 9048 of chart 9038 andbars 9040 through 9047 indicate the I/O combinations during an extendclamp request. Chart 9038 is divided into three separate I/Ocombinations named “all retracted”, “intermediate” and “all extended”.Initially, referring only to the first cylindicator 9425, at left edge9048, the retracted proximity input signal (bar 9046) is activeindicating that the cylindicator piston is in the retracted position. Toextend the piston, at edge 9048, both terminals of the two-positionvalve extend solenoid and both terminals of the spring return valveextend solenoid are activated (see bars 9040, 9041, 9044 and 9045). Fora short time the all retracted conditions persist until the retractproximity sensor no longer senses the cylindicator piston.

During the period when neither the extended nor retracted sensors sensethe cylindicator piston, the intermediate conditions exist. During thisperiod, the extend solenoids of each of the two-position andspring-return valves remain excited (see bars 9040, 9041, 9044 and 9045)so that the piston and clamp surface secured thereto continue to movetoward the extended position.

Eventually the extended proximity sensor senses the cylindicator pistonand generates an active input (see bar 9047) and the all extendedconditions occur. During this time and until the extend commandsubsides, each of the valve extend solenoids remain activated. Similarinput conditions occur for cylindicators 9427, 9429 and 9431 during anextend request.

Retract chart 9032 also includes a sequence section 9064 and aproperties section 9066. Properties section 9066 is explained below.Sequence section 9064 includes a bar chart 9068 including a separate barfor each of the inputs and outputs in I/O tables 8510 a-8510 d, 8610 and8710, respectively. Once again, chart 9068 is separated into sixsections only for illustrative purposes and would more likely appear asa single table.

The retract clamp request begins at the left edge 9070 of chart 9068 andthe bars of chart 9068 indicate I/O combinations during a retract clamprequest. Chart 9068 is again divided into three separate I/O sectionsnamed “all extended”, “intermediate” and “all retracted”. Initially,referring only to cylindicator 9425, at left edge 9070, the extendedproximity input signal is active (see bar 9071) indicating that thecylindicator piston is in the extended position. To retract the piston,at edge 9070, both terminals of the two-position valve retract solenoid(see bars 9073 and 9075) are activated. For a short time the allextended conditions persist until the extend proximity sensor no longersenses the cylindicator piston.

During the period when neither the extended nor retracted sensors sensethe cylindicator piston, the intermediate conditions exist. During thisperiod, the retract solenoid of the two-position valve remains excitedso that the piston and clamp surface secured thereto continue to movetoward the retracted position.

Eventually the retracted proximity sensor senses the cylindicator pistonand generates an active input and the all retracted conditions occur.During this time and until the retract command subsides, thetwo-position valve retract solenoid remains activated. Similar inputconditions occur for cylindicators 9427, 9429 and 9431 during an extendrequest.

It is also contemplated that a resource editor will configure aninterface screen which resembles the image illustrated in FIG. 85. It iscontemplated that resource editor is useable to parameterize unique CAinstances as will be explained in more detail below.

Thus, logic specification 9002 defines I/O combinations during eachpossible request for a mechanical resource which is associated with theCA. In the case of the exemplary clamp, the requests include extend andretract requests including the sequences of I/O combinations illustratedin FIG. 85.

ii. Schematic Specification

Referring again to FIGS. 84 and 85 and also to FIG. 85A schematicspecification 9004 includes a table 8001 including a list 8003 of thecontrol devices in logic section 9002. The list 8003 includes deviceswhich are optional in the CA 9000 as will be explained in more detailbelow. In the present example optional devices include the spring returnvalve 9423 and the second through fourth cylindicators 9427 through9431.

iii. HMI Specification

Referring to FIG. 84, HMI specification 9006 may take any of severaldifferent forms. Referring also to FIG. 86, in a preferred embodimentHMI specification 9006 includes an HMI specification table 9460.Consistent with the present example, table 9460 includes informationspecifying all possible monitorable and controllable I/O for the1stclamps CA instance. To this end, table 9460 includes a device column9462, a monitorable I/O column 9464 and a controllable output/requestcolumn 9466. Device column 9462 includes a listing of all possiblecontrol devices which can be included in a particular assembly. In thepresent example, possible 1stclamps control devices include two-positionvalve 9421, spring return valve 9423 and first through fourthcylindicators 9425, 9427, 9429 and 9431, respectively.

I/O column 9464 lists all monitorable I/O corresponding to controldevices in column 9462. To this end, all of the outputs corresponding totwo position valve 9468 are monitorable and therefore, each of thoseoutputs (i.e. O1, O2, O3, O4) are listed in column 9464 in the rowcorresponding to valve 9421. Both outputs O5 and O6 of spring returnvalve 9470 are monitorable and therefore, each of those outputs appearsin column 9464. First, cylindicator 9425 includes two outputs I1 and I2,each of which are monitorable, and each of which appears in column 9464in the row corresponding to first cylindicator 9425. Similarlycylindicators 9427, 9429 and 9431 each have two inputs which aremonitorable and which appear in column 9464.

Controllable outputs/requests column 9466 includes a list of all outputscorresponding to the control devices in column 9462 which arepotentially manually controllable via an HMI. To this end, all of thetwo position valve outputs O1, O2, O3 and O4 are provided in column 9466in the row corresponding to valve 9421. Both outputs O5 and O6 of springreturn valve 9423 are included in column 9466. None of cylindicators9425-9431 include outputs and therefore blanks corresponding to each ofthe cylindicators appear in column 9466.

In addition to controllable outputs, potentially manually controllablerequests are also provided in column 9466. In the present case, thereare only two requests which correspond to the 1stclamps CA instanceincluding extend request 9031 and retract request 9033. Each of requests9031 and 9033 correspond to the similarly named requests in logicspecification 9002 (see FIG. 85) and each is listed in column 9466.

When any of the outputs or requests in column 9466 is selected formanual control, a manual control request 9035 is also selected.Subsequently, when an HMI is configured, the HMI provides means forcontrolling each of the selected outputs and selected requests in column9466 as will be explained in more detail below and provides means forobserving each of the selected inputs. Referring to FIGS. 85 and 86, itshould be appreciated that table 9460 includes a large number ofmonitorable I/O and controllable outputs and requests. While such anextensive table 9460 is possible for each CA, whether or not table 9460is extensive is a matter of choice for the engineer who designs theinitial CA template. For example, the engineer designing the initial CAtemplate may have, instead of providing an exhaustive table 9460,provided a table wherein only cylindicator inputs are monitorable andthe valve outputs O1 through O6 would not be monitorable. Similarly, theengineering designing the template may have decided that only the extendand retract requests 9490, 9492, respectively, should be controllableand that the outputs for the valves 9468 and 9470 should not becontrollable.

In addition, it should be appreciated that table 9460 is simply a dataconstruct for keeping track of selected control devices andcorresponding selected monitorable I/O and controllable outputs andrequests. It is contemplated that other interface tools to be describedbelow are used to select and deselect control assemblies and monitorableand controllable signals and requests and that table 9460 is simply usedto track selection and de-selection facilitated via the other tools.

iv. Diagnostic Specification

Referring again to FIG. 84, diagnostic specification 9008 serves as arepository for control device diagnostic rules which have been designedinto the CA template by the engineer who configured the template.Referring also to FIG. 87, diagnostic specification 9008 includes adiagnostic specification table 9600. Table 9600 includes informationspecifying all possible diagnostic requirements and correspondingactivities which may be selected for support by a subsequently compiledexecution code. Table 9600 includes three columns including adevice/request column 9602, a requirement column 9604 and an activitycolumn 9606.

Column 9602 includes a list of devices which include built-indiagnostics. In the present case, first clamps includes at least a firstcylindicator 9425 which supports diagnostics. Referring again to FIG.81, when a failure condition occurs wherein both the extended andretracted proximity sensors indicate presence of a cylindicator piston(see 5418), the diagnostics portion of the control device shouldindicate, via an HMI, the text “cylindicator sensor failure.” Thus,first cylindicator 9425 is listed within column 9602. Similarly, each ofthe second, third and fourth cylindicators also correspond to diagnosticmessaging when a failure condition occurs. Therefore, each of thesecond, third and fourth cylindicators 9610, 9612 and 9614 appear incolumn 9602.

In addition to the cylindicators, exemplary requests associated with“interesting conditions” are also provided in column 9602. The exemplaryrequests include extend and retract requests 9616 and 9618 correspondingto the 1st cylindicator 9425 input signals.

Requirement column 9604 indicates the specific diagnostic conditionwhich must occur for corresponding diagnostic activity in column 9606 totake place. Thus, for example, the requirement in column 9604corresponding to first cylindicator 9425 is a failure condition 9622(i.e. each of the extended and retracted proximity sensors in FIG. 81must indicate piston location at the same time). In this case, referringto FIGS. 87 and 81, the activity in column 9606 corresponding to failure9622 is to provide text 8517 indicating “cylindicator sensor failure”.Similar requirements and activities correspond to each of the second,third and fourth cylindicators 9427, 9429 and 9431, respectively.

Referring still to FIG. 87, the requirement 9624 corresponding to theextend request for first cylindicator 9425 is that input I1 remainpassive. When input I1 remains passive after an extend request isissued, this indicates that the extended proximity sensor does notgenerate an active input signal I1 and therefore, for some reason, anerror in the system has occurred. The activity corresponding to apassive input I1 is to indicate an error 9626. A similar requirementcorresponds to the retract request for cylinder C1 as illustrated.

It should be appreciated that, while several diagnostics requirementsand activities have been provided in table 9600, table 9600 is by nomeans exhaustive and other diagnostics devices and requests andcorresponding requirements could be specified and, certainly, otheractivities could also be specified. Thus, table 9600 is meant to beexemplary only and not exhaustive.

One particularly useful type of diagnostics which is preferably includedin the diagnostics specification is referred to as “status based” orsimply “status” diagnostics. Status diagnostics includes diagnosticswhich, instead of providing a likely diagnosis of a specificallyidentified abnormal or interesting condition, simply indicates the nextexpected event in a control process. Thus, when a line shuts downbecause of a malfunction, an operator can determine the next event and,based thereon, can typically determine how to eliminate the conditionwhich caused the line to stop.

One way to facilitate status based diagnostics is for a programmer to gothrough an entire RLL program and, for each event which occurs duringthe program, provide status code which, prior to the even occurring andsubsequent to the occurrence of a preceding event, indicates the statusof the next event to occur via a displayed text message. Unfortunately,the programming task of providing such diagnostic code is so timeconsuming and complex that such a task is impractical and is notattempted despite the advantages which would result.

Importantly, the reusable CA model for programming, execution logic anddiagnostics can be used to facilitate status based diagnosticsprogramming. This is because each CA diagnostics specification caninclude status based diagnostic messages for each event which occursduring one of the CA requests. Each time a new instance of a CA isinstantiated, a CA request is sequenced in a control bar chart and therequests are compiled, the code supporting the status based diagnosticsmessages can be duplicated and interspersed throughout the executionlogic code. In this regard, the status based code is added to theexecution code and has nothing to do with operation of the executioncode. The status based code simply identifies the next event to occurand then generates a text message for visual display indicating the nextevent to occur. Once the next event to occur has been achieved, thediagnostics displays the next event to occur and so on.

Which events should be reported is a matter of designer choice. Forexample, for a specific request, several events may take place. Forinstance, to extend a clamp, a first event may be extension of a valveand a second event may be extension of a cylindicator associated withthe clamp. In this case, either one or both of the events correspondingto the request may be supported by status based diagnostics. In oneembodiment only termination events are supported by status baseddiagnostics where termination events are the last events which occur ina request and where commencement of subsequent requests depends oncompletion of the termination events. In other embodiments intermediateevents (i.e. non-termination events) are also supported.

Referring also to FIG. 87A, an exemplary status based diagnosticsspecification 3501 corresponding to the 1st clamps CA is illustrated.Specification 3501 includes a specification table 3503 includinginformation specifying all 1st clamps CA requests and all requestevents. To this end, table 3503 includes a request column 3505, arequirement column 3507 and an activity column 3509.

Column 3505 includes a list of all 1st clamps CA requests. Referringalso to FIG. 85, 1st clamps include only two requests including extendand retract requests 9031 and 9033, respectively and therefore extendand retract requests 3511 and 3513, respectively, appear in column 3505.

Requirements column 3507 include consecutive I/O combinations whichcorrespond to events which must occur during an associated request (e.g.in this case an extend or retract request). For example, referring toFIGS. 85 and 87A, when an extend 9031 1st clamps request is made first,two position valve 9421 must be activated. Valve 9421 is activated whenoutputs 01 and 02 are high and outputs 03 and 04 are low. Thus, therequirement for two-position valve activation is 01=1; 02=1; 03=0 and04=0. All of the other 1st clamps I/O have nothing to do with the status(i.e., active or inactive) of two-position valve 9421. In column 3507other I/O for which the status is not important for a specific event areidentified as “don't care” I/O by a “−”. Thus, the requirement for thetwo-position valve extend event is I/O combination 3515.

Referring still to FIGS. 85 and 87A, the next event to occur during the1st clamps extend request is a spring return valve extend event whichoccurs when outputs 05 and 06 are high. The status of all other 1stclamp I/O is unimportant with respect to the spring return valve extendevent. The I/O combination requirement in column 3507 for the springreturn valve extend event is identified by numeral 3517.

Note that in reality, both two-position valve 9421 and spring-returnvalve 9423 would achieve their respective extend states simultaneously.Nevertheless, by providing status based diagnostics which checks eventsconsecutively, each event is reported separately and if one event doesnot occur, the single event which does not occur is reported for anoperators observation.

Referring again to FIGS. 85 and 87A, the next event to occur during a1st clamps extend request is a 1st cylindicator extended event whichoccurs when input I1 is high and input I2 is low. This event correspondsto I/O combination requirement 3519 in column 3507. Although notnumbered, column 3507 includes other I/O combination requirements whichcorrespond to extended second, third and fourth cylindicators 9427, 9429and 9431, respectively.

Similarly, column 3507 also includes I/O combination requirementscorresponding to consecutive events which occur during the 1st clampsretract request (see 9033 in FIG. 85). For instance, a two-positionretract event is identified by numeral 3521.

Column 3509 includes a single activity corresponding to each requirementin column 3507. For example, activity 3523 corresponds to thetwo-position value extend event requirement 3515 and specifies text“two-position valve extend” to be displayed. Similarly, activity 3525specifying text “spring-return valve extend” corresponding to thespring-return valve extend event requirement 3517 and so on.

Activities in column 3523 are performed from the time when a previousevent is completed until the time the corresponding requirement incolumn 3507 occurs. For example, after a request prior to a 1st clampsextend request has been completed, message “two-position valve extend”is displayed until I/O combination requirement 3515 is achieved. Afterrequirement 3515 is achieved message “spring-return valve extend” isdisplayed until requirement 3517 is achieved. After requirement 3517 isachieved message 1st cylindicator extended” is displayed and so on.

v. Simulation Specification

Referring again to FIG. 84, simulation specification 9300 is used tofacilitate virtual three dimensional CAM simulation using real world PLCexecution code generated by compiling control logic. The execution codespecifies I/O for specific control mechanisms which in turn controlmechanical resources linked thereto. When linked to the controlmechanisms correctly, the execution code causes a prescribedmanufacturing process to be performed.

It has been recognized that in the virtual world, while the mechanicalresources which form a manufacturing line and their possible movementscan be represented by video clips of the resources in operation,unfortunately, control mechanisms have no virtual representation. Thus,while the execution code specifies I/O for controlling virtualmechanical resources via control mechanisms, because there are novirtual control mechanisms, there is a disconnect between the executioncode and the virtual mechanical resources.

Exemplary specification 9300 effectively maps the PLC outputs tocorresponding video clips of the virtual mechanical resources. Inaddition, simulation specification 9300 also maps signals correspondingto specific occurrences in the video clips back to the PLC as PLCinputs.

Referring now to FIG. 88, an exemplary simulation specification 9300corresponding to 1stclamps logic specifications 9002 is illustrated andincludes video tables and feedback tables for each of the four possiblecylindicators 9425-9431. Thus, for the first cylindicator 9425,specification 9300 includes video table 9302 and feedback table 9304.For the second cylindicator 9427, specification 9300 includes videotable 9303 and feedback table 9305 and, although not illustrated,similar video and feedback tables are provided for third and fourthcylindicators 9429 and 9431, respectively. Each of the video tables issimilar and therefore, to simplify this explanation, only tables 9302and 9304 are explained here in detail.

Video table 9302 includes an I/O combination column 9306 and a videoclip column 9308. Combination column 9306 includes an I/O row 9310 whichlists all of the I/O in logic specification 9002 which is associatedwith operation of the first cylindicator 9425 to move an associatedclamp. Thus, row 9310 includes outputs 01 through 06 and inputs I1 andI2. In the video and feedback tables corresponding to the second, thirdand fourth cylindicators 9427-9431, combination columns would beessentially identical to column 9306 except that inputs I1 and I2 wouldbe I3, I4; I5, I6; and I7, I8, respectively.

Referring still to FIG. 88, below row 9310 is a list of I/O combinationswhich includes every possible I/O combination corresponding to the I/Oin row 9310. In the column 9306 list, a “1” indicates an active signal,a “0” indicates a passive signal and a “−” indicates a “don't care”condition. Thus, for example, the first I/O combination 9312 includesactive outputs O1, O2, O5 and O6, passive outputs O3 and O4, a passiveinput I1 and the state of input I2 does not matter.

Video clip column 9308 includes a list of video clip indicatorscorresponding to the I/O combinations in the rows of column 9306. In thepresent example (i.e. a clamp associated with the first cylindicators),only three possible video clips can occur. The first video clipidentified by “1” corresponds to a video illustrating a clamp extending.A second video clip identified by “2” corresponds to a videoillustrating a clamp retracting. The third video clip “3” corresponds toa video illustrating a stationary clamp.

Referring to FIGS. 85 and 88, the first combination 9312 corresponds toan extend request in logic specification 9002 and, as desired, isassociated with the extend video clip 1 (9314). The second I/Ocombination 9316 in column 9306 includes outputs which correspond to anextend request in specification 9002. However, input I1 is also activeindicating that the extend video has already occurred. In this case, thecombination 9316 corresponds to the stationary video 3 (9318).Continuing, the fourth I/O combination 9320 includes all passive outputsand a passive second input I2. In the case of first clamps, a passiveinput I2 indicates that the clamp is not yet in the retracted position.In addition, because all outputs O1 through O6 are passive, the springin the spring return valve should force the clamp into the retractedposition. Therefore, the video clip corresponding to fourth I/Ocombination 9320 is clip 2 (9322) which shows the clamp retracting.

Thus, table 9302 receives PLC I/O combinations corresponding to a firstclamp to be controlled and maps each combination to a specific videoclip which illustrates what a clamp in the real world would be expectedto do as a result of the specific I/O combination. Video tables for thesecond, third and fourth clamps which are controllable via the firstclamps CA operate in a similar fashion.

Referring still to FIG. 88, feedback table 9304 includes both an eventcolumn 9324 and a feedback column 9326. Event column 9324 includesevents corresponding to specific occurrences in video clips which shouldbe linked to PLC inputs. In the present example, the 1stclamps inputsinclude extended proximity and retracted proximity signals I1 and I2which should change from passive to active when an associated clampvideo reaches fully extended and fully retracted positions,respectively. In the case of the clamp videos, the fully extendedposition is achieved at the end of video clip 1 and the fully retractedposition is achieved at the end of video clip 2. Therefore, the eventsin column 9324 include video clip 1 complete and video clip 2 complete.

Feedback column 9326 includes feedback input signals for the PLCcorresponding to each event in column 9324. For example, at the end ofvideo clip 1, input I1 is set equal to 1 and input I2 is set equal to 0.Similarly, at the end of video clip 2 when the clamp achieves the fullyretracted position, input I1 is set equal to 0 and input I2 is set equalto 1 indicating a fully retracted clamp.

It should be appreciated that the tables 9302 and 9304 in FIG. 88 arenot exhaustive and that other combinations in corresponding video clipscould be added to table 9302 and other events and corresponding feedbackcould be added to table 9304.

In addition, it should be appreciated that, instead of being used with avideo module which plays video clips, the simulation specification maybe used in conjunction with a CAD or CAM system which can simulatethree-dimensional movement of three-dimensional virtual mechanicalresources on the display of a work station. In this case instead ofmapping I/O combinations to specific video clips, the I/O combinationsmay be mapped to specific requests in a mechanical resource timingdiagram which in turn cause the CAD or CAM system to displaycorresponding mechanical resources in operation. In addition, in thiscase, instead of linking feedback events to specific occurrences invideo clips, the feedback events would be linked to specific occurrencesduring CAD or CAM simulation. Moreover, other types of simulationspecification are contemplated and are described in more detail below.

b. CA Parameterization

While it would be preferable if all controls information in a CA werecompletely rigid, unfortunately, as indicated in the Background sectionabove, such a system would likely result in an unworkably large numberof CAS. For example, for clamps, if there were five clamp CA features inaddition to basic (i.e., a valve and a cylinder) clamp CA requirements,the number of different feature combinations would require a huge numberof separate clamp CAS.

To avoid requiring a massive CA template library, the inventive CAtemplates have been designed to strike a compromise betweenparameterization and permanently specified controls information. Whileeach of the CAS include predefined controls information, some or all ofthe CAS may include information which can be “parameterized” or“customized”. In this context the term “parameterized” means that aportion of the CA can be modified so that CA features accommodatespecific design requirements.

While many schemes for facilitating parameterization are contemplated bythe present invention, in the interest of simplifying this explanation asingle parameterization scheme will be described. In the exemplaryscheme each CA template defines all of the control information which isrequired to support a maximum number of control devices andcorresponding HMI characteristics, diagnostics and simulation. However,at least some of the control information defined in each parameterizableCA is selectable and de-selectable via parameterization tools to bedescribed. When CA information is selected, the information is said tobe instantiated in the specific CA instance and is subsequently used bya compiler to generate a control execution code, to configure an HMI, togenerate schematics and to provide simulation tools. Information whichis not selected and instantiated is said to “exist” in the CA instancebut is not subsequently used during compilation to generate executioncode, configure an HMI, provide control system schematics or to supportvirtual system simulation.

Generally, two types of parameterization referred to as “propertysetting” and “feature selection” are contemplated. Referring again toFIG. 85, property setting parameterization involves properties sections9036 and 9066. Properties section 9036 includes indicators forindicating specific properties of the 1stclamps CA instance extendrequest. To this end, the indicators include a latch set 9050, a restartset 9052 and an inverse request set 9054. Latch set 9050 indicateswhether a latch (i.e. a switch) should be set at the end of the extendrequest. When a latch is set, the latch can be used as a trigger or acondition for other system requests. The latch set 9050 is set when aflag (i.e. a check) appears in the flag box 9051. In FIG. 85 the latchset is not set.

Restart set 9052 indicates whether or not the extend request isrestartable. Restartable means that during execution of a request, ifanother identical request is initiated, the second request can restartthe request cycle. Some requests cannot be restarted. For example, aparticular sequence of robot movements most often would not berestartable without modifying an end result. For instance, if a requestrequires a robot to move a welding point 12 inches forward and 10 inchesto the left during a request, after the robot moves 8 inches forward, ifthe request was restarted, the end result would be incorrect.

Referring still to FIG. 85, in the case of the extend request cycleindicated by chart 9038, it makes no difference during an extend requestif another extend request is received, the second extend request canrestart the cycle. Thus, a check in a “restartable” flag box 9053indicates a restartable request.

Inverse request set 9054 indicates the inverse request for the extendrequest. Virtually all requests include an inverse request which is theinverse of the request which returns a mechanical resource back to aninitial state. For example, in the case of a clamp, the inverse of anextend request is often a retract request. In the case of a robot, theinverse of a request moving 12 inches forward and 8 inches to the leftmay be to move 8 inches to the right and 12 inches rearward. While onlyextend and retract requests are illustrated in FIG. 85, mechanicalresources other than a clamp may have many more than two requestsspecified in their logic specifications 9002. For example, in the caseof a robot, a robot may have ten different requests which can be calledto cause the robot to cycle through ten different movement sequences. Inthis case, five of the requests may by the inverse requests for theother five requests and the inverse requests would be indicated usingthe inverse request set 9054 and an accompanying window 9056. In thepresent case, window 9052 indicates the inverse request as the retractrequest specified by retract request chart 9032. Referring again to FIG.85. Properties section 9066 is similar to section 9036 and thereforewill not be explained again in detail. The main difference betweensections 9036 and 9066 is that the inverse request set 9084 in section9066 indicates the extend request instead of the retract request.

The 1stclamps request properties in properties sections 9036 and 9066are an example of features which are parameterizable via propertysetting. Thus, when the 1stclamps CA instance is instantiated, thecontrol engineer can specify if a latch should be set at the end of theextend request (see latch set 9050), if the extend request is to berestartable (see restart set 9052) and which request is the inverse ofthe extend request (see inverse request set 9054). Similarparameterization is enabled in properties section 9066.

The second type of parameterization, feature selection, as the nameimplies, simply provides a control engineer the option to select orde-select optional CA control features for compilation which, althoughdesired in certain applications, are not required in all applications.To this end, some of the devices in CA logic specification 9002 arerequired and others of the listed devices are not necessarily requiredfor the 1stclamps CA to operate properly.

In addition, some of the control devices are included in the CA templateas default devices whereas others of the listed control devices mayoptionally be added to the CA as required. Optional default controldevices can be deselected so that they are effectively removed from aspecific CA instance. For example, the devices in specification 9002include three default control assemblies including two position valve9421, spring return valve 9423 and 1st cylindicator 9425. Of the threedefault control devices 9421, 9423 and 9425, it is assumed that only thetwo position valve 9421 and first cylindicator 9425 are required, thespring return valve 9423 being optional.

Throughout FIGS. 85, 85A, 86, 87, 87A and 88, a plurality of flag boxes(e.g. 9480 a, 9482 a, 9484 a, 9486 a, 9480 b, 9480 c, etc.) areprovided, each of which corresponds to a CA device or characteristicwhich may be selected or de-selected to parameterize a specific CAinstance. Flag boxes which include a flag (e.g. see box 9480 a in FIG.85) indicate selection or designation and boxes which are clear (e.g.see box 9991 in FIG. 86) indicate un-selected or un-designated devicesor characteristics.

Generally there are two different types of flag boxes, designation boxesand selection boxes. On one hand, a designation box is used to designatean associated device, characteristic or characteristic set as an itemwhich is later presented as a selectable item for additionalparameterization. Thus, a characteristic or characteristic set which isdesignated by a flag in a designation box is not instantiated but islater presented for possible instantiation. On the other hand, aselection box is used to select and instantiate a correspondingcharacteristic for subsequent compilation.

Referring again to FIG. 85, to indicate the optional nature of springreturn valve 9423, a selection box 9480 a is provided adjacent valve9423. Initially, as value 9423 is a default control device, a flag mark(i.e. check) appears within box 9480 a. Because each of control devices9468 and 9472 are required, flag boxes are not provided adjacent thosetwo control devices in column 9462. It is contemplated that a tool willbe provided for de-selecting valve 9423 by removing the flag from box9480 a. One such tool is described below.

In addition to default control devices 9421, 9423 and 9425, the devicesin the “SafeBulkHeadClampSet” CA template logic specification 9002 alsoincludes three optional control devices including second, third, andfourth cylindicators 9427, 9429 and 9431. Because each of cylindicators9427-9431 can optionally be selected or deselected to remove,respectively, the cylindicators from the control assembly, selectionboxes 9482 a, 9484 a and 9486 a are provided adjacent each of thecylindicators 9427, 9429 and 9431, respectively. While flags areprovided in boxes 9482 a, 9484 a and 9486 a, initially, because each ofcylindicators 9427-9431 are not default control devices, flags would notbe provided in boxes 9482 a, 9484 a and 9486 a. If cylindicators9427-9431 are selected flags are placed within corresponding selectionboxes to indicate selection. FIG. 85 reflects the state of boxes 9482 a,9484 a and 9486 a after selection of cylindicators 9427-9431.

Referring to FIGS. 85 and 85A, separate selection boxes 9480 f, 9482 f,9484 f and 9486 f which correspond to selection boxes 9480 a, 9482 a,9484 a and 9486 a, respectively, are provided adjacent representations“spring return valve” 9423, “2nd cylindicator” 9427, “3rd cylindicator”9429 and “4th cylindicator” 9431, respectively. As described below, whena selection or de-selection is made in specification 9002, selectionripples through schematics specification 9004 providing flags incorresponding selection boxes 9480 f, 9482 f, 9484 f and 9486 f. Asindicated above, flags in any of boxes 9480 f-9486 f indicate thatsubsequently, when the schematic is compiled and constructed for the1stclamps CA instance, the compiler must include representations in theschematic for corresponding control devices (e.g. spring return valve9423, 2nd cylindicator 9427, etc.) Initially, because spring returnvalve 9423 is a default control device, a flag appears in box 9480 f.Similarly, because each of cylindicators 9427, 9429 and 9431 are notdefault devices, initially no flags appear in boxes 9482 f, 9484 f and9486 f. FIG. 85A shows the state of boxes 9482 f, 9484 f and 9486 fafter corresponding cylinders have been selected for inclusion in the1stclamps CA instance.

Referring to FIGS. 85 and 86, separate designation boxes 9480 b, 9482 b,9484 b and 9486 b which correspond to selection boxes 9480 a, 9482 a,9484 a and 9486 a, respectively, are provided next to therepresentations “spring return valve” 9423, “cylindicator-2” 9427,“cylindicator-3” 9429 and “cylindicator 4” 9431, respectively. Asdescribed below, when a selection or de-selection is made inspecification 9002, the selection ripples through HMI table 9460providing flags in corresponding designation boxes 9480 b, 9482 b, 9484b and 9486 b. Boxes 9482 b, 9484 b and 9486 b include flags indicatingdesignation.

In addition, a separate selection box (e.g. 9991) is provided under eachof outputs O1 through O4 for indicating selection of those outputs to besupported by a corresponding HMI. For each of outputs O1 through O4which is selected to be monitored via an HMI, some type of an HMIindicator is specified during subsequent compilation which correspondsto the selected output. As illustrated in FIG. 86, none of the outputselection boxes includes a flag and therefore none of the outputs areselected. Selection boxes (e.g. 9493, 9495) are also provided foroutputs 05 and 06 and for each input I1-I8 in column 9464. Asillustrated, boxes 9493 and 9495 include flags and therefore have beenselected.

Referring still to FIG. 86, as with the outputs listed in column 9464, aseparate selection box is provided for each of outputs in column 9466 toindicate whether or not the corresponding outputs are selected to beincluded in the HMI. As illustrated, none of the outputs are presentlyselected (i.e. the selection boxes are empty). Also, selection boxes areprovided each of outputs 05 and 06 in column 9466. Selection boxes 9490,9492 are also provided adjacent “extend” and “retract” requests incolumn 9466. Boxes 9490 and 9492 include flags indicating selection.

Referring to FIGS. 85 and 87, separate designation boxes 9482 c, 9484 cand 9486 c which correspond to boxes 9482 a, 9484 a and 9486 a,respectively, are provided next to cylindicators 9427, 9429 and 9431,respectively. As described below, when a selection or de-selection ismade in specification 9002, the selection ripples through diagnosticstable 9600 providing a flag in a corresponding designation box 9482 c,9484 c or 9486 c. In addition, selection boxes 2001, 2002, 2003, etc.are provided next to each requirement in list 9604 to enable furtherparameterization as described below. Each of boxes 9482 c, 9484 c and9486 c include flags indicating designation while box 2001 includes aflag indicating selection.

Referring to FIG. 87A, where a status based diagnostics specification isemployed, separate designation boxes, 9480 g, 9482 g, 9484 g and 9486 gwhich correspond to boxes 9480 a, 9482 a, 9484 a and 9486 a (see FIG.85), respectively, are provided next to spring return valve extendrequirement 3520 and so on. Similarly, boxes 9480 g, 9482 g, 9484 g and9486 g are provided next to return request event requirements which areassociated with spring-return valve 9423, second cylindicator 9427,third cylindicator 9429 and fourth cylindicator 9429. Once again, when aselection or de-selection is made in specification 9002. The selectionripples through diagnostics table 3503 providing or eliminating a flagin corresponding designation boxes 9480 g, 9482 g, 9484 g and/or 9486 g.

With respect to status based diagnostics, when a designation box isblank, upon compilation status based diagnostics code is not providedfor a corresponding event. For example, referring to FIGS. 85 and 87A,where box 9480 a is deselected to remove the flag therein, thede-selection ripples through table 3501 and removes the flag from boxes9480 g. Then, upon compilation, the status based diagnostics specifiesthat after requirement 3515 is achieved, requirement 3519 corresponds tothe next event and the displayed status based diagnostics message is“1st-cylindicator extended.”

Referring to FIGS. 85 and 88, selection boxes 9480 c, 9480 d and 9480 ewhich correspond to box 9480 a are provided in video table 9302. Box9480 c corresponds to column 9037 below output 05. When the springreturn valve 9423 is selected, output 05 exists and therefore shouldaffect table 9302. However, when valve 9423 is deselected, output 05does not exist and hence must not affect the video to be displayed. Anempty selection box 9480 c renders data in column 9037 under output 05ineffective. The remaining I/O combinations are still effective formapping purposes. Box 9480 d has a similar relationship to output 06 andcolumn 9039 therebelow.

Box 9480 e corresponds to the I/O combination 9320 to the right thereofin column 9306. In the present example, if spring return valve 9423 isde-selected, certain I/O combinations, including the combination to theright of box 9480 e, are incorrect and therefore should not affect thevideo to be displayed. An empty selection box 9480 e renders I/Ocombination 9320 to the right thereof ineffective.

Referring still to FIGS. 85 and 88, selection boxes 9482 d and 9482 eare provided in tables 9303 and 9305 which correspond to box 9482 a.When cylindicator 9427 is selected in specification 9002, simulationtables like tables 9302 and 9304 must be provided for the secondcylindicator 9427. To this end, flags in boxes 9482 d and 9482 e selectand instantiate tables 9303 and 9305 for subsequent compilation. Boxes9482 d and 9482 e each include a flag and therefore indicate selectionof corresponding tables 9303 and 9305, respectively. Although notillustrated, similar selection boxes are provided for video and feedbacktables corresponding to third and fourth cylindicators 9429 and 9431,respectively.

Referring to FIG. 85, as indicated above, spring return valve 9423 is aninitial default control device but is optional. Referring to FIGS. 84and 85 if valve 9423 is de-selected using an editor described below andas indicated by removing the flag from box 9480 a, de-selection ripplesthrough each CA specification 9004, 9006, 9008 and 9300 to modify tablestherein to reflect de-selection.

To this end, referring to FIGS. 85 and 85A, initially a flag appears inbox 9480 f indicating a default device and that spring return valve 9423must be represented in a CA schematic representation upon compilation.However, when the flag is removed from box 9480 a (see FIG. 85), theflag in box 9480 f is also removed. When the flag in box 9480 f isremoved, spring return valve 9423 is de-selected and, upon compilation,will not be represented in the CA schematic. Referring to FIGS. 85 and86, initially, a flag appears in box 9480 b indicating a default controldevice and indicating that I/O in columns 9464 and 9466 willsubsequently be presented for selection and instantiation via an HMIeditor (i.e., corresponding I/O in columns 9464 and 9466 has beendesignated for subsequent possible selection and instantiation).However, when the flag is removed from flag box 9480 a in logicspecification 9002, the flag in box 9480 b is also removed. Thepractical effect of removing the flag from box 9480 b is thatmonitorable I/O in column 9464 and controllable output in column 9466corresponding to valve 9423 are undesignated and therefore, uponsubsequent presentation of monitorable and controllable I/O forselection and instantiation, these I/O are not presented.

Referring to FIG. 87, diagnostic specification table 9600 does notspecify diagnostics for the spring return valve and therefore no flagsare modified in table 9600 when spring return valve 9423 is de-selectedin logic specification 9002.

Referring to FIG. 88, selection boxes 9480 c and 9480 d are provided foroutputs 05 and 06 which correspond to spring return valve 9423 and whichare associated with flag box 9480 a. Initially, because valve 9423 is adefault control device, flags are provided in each of boxes 9480 c and9480 d meaning that outputs 05 and 06 in column 9306 are to be includedin I/O combinations. When the flag is removed from box 9480 a, the flagsin boxes 9480 c and 9480 d are also removed thereby effectivelyde-selecting and eliminating outputs 05 and 06 from the combinations incolumn 9306.

In addition, when outputs 05 and 06 are eliminated by de-selection, someof the video clips corresponding to combinations in column 9306 may berendered incorrect. For example, referring still to FIGS. 85 and 88 andspecifically to combination 9320, if spring return valve 9423 isde-selected, because the safety spring in the return valve iseliminated, when all of inputs 01 through 04 are passive (i.e. zeros),the clamp linked to the first cylinder will remain stationary. For thisreason, the retract video clip 9322 is incorrect. Thus, selection boxes(one illustrated) 9480 e corresponding to combination/video clips whichare to be de-selected and hence rendered un-instantiated uponde-selection are provided adjacent each such combination. Once again,initially a flag appears in box 9480 e as spring return valve 9423 is adefault device.

Referring to FIG. 84, all other controls information in CA 9000 is alsoupdated when a second cylindicator control device is selected and addedto CA 9000 to control a second clamp. Referring to FIGS. 85 and 86, whena flag is placed in selection box 9482 a, a flag is also placed indesignation box 9482 b. A flag in box designation 9482 b indicates thatthe monitorable and controllable I/O corresponding to the secondcylindicator 3 should be subsequently presented for selection andinstantiation via an HMI editor. In the present example secondcylindicator 9427 includes inputs I3 and I4 which are monitorable andincludes no controllable outputs.

Referring to FIGS. 85 and 87, when a flag is placed in box 9482 a, acorresponding flag is placed in designation box 9482 c indicating thatthe requirement and activity in the row corresponding to the secondcylindicator 9427 should be subsequently provided for selection andinstantiation via a diagnostics editor. If box 9427 is empty,corresponding requirements/activities are not subsequently provided forselection.

Referring to FIGS. 85 and 88, when a flag is placed in selection box9482 a, corresponding flags are placed in selection boxes 9482 d and9482 e. Flags in boxes 9482 d and 9482 e select and instantiate tables9303 and 9305 for subsequent compilation.

Referring to FIGS. 85, 85A, 86, 87 and 88, each of the selection boxes9484 a and 9486 a correspond to designation and selection boxes in eachof schematics table 800, HMI table 9460, diagnostics table 9600 andsimulation specification 9300 and, as with box 9482 a, flags in boxes9484 a and 9486 a ripple through tables 800, 9460 and 9600 and throughspecification 9300 to designate (i.e., designate information forsubsequent selection) and select (i.e., instantiate information forsubsequent compilation), respectively.

In this manner, any change to logic specification 9002 ripples throughother specification sections of control assembly 9000.

4. Control Sequence Bar Chart

CA requests can be sequenced to cause a plurality of mechanicalcomponents to operate in a specified order to carry out a manufacturingprocess. Referring to FIG. 89, preferably, the sequencing process isaccomplished using a control bar chart 9700. Chart 9700 includes acontrol resource column 9702, a requests column 9704 and a bar chartdiagram 9706 which corresponds to the columns 9702 and 9704. Theresources column 9702 includes a list of CA instances which have beenchosen to control the mechanical resources (not illustrated) which areassociated with a specific manufacturing process. To this end, asillustrated, the CAS include controllers, pins, clamps, dumps, locatorsand so on. One of the specified CA instances is the 1stclamps CAinstance described above which appears twice in column 9702 at 9708 and9709.

Requests column 9704 includes a list of requests corresponding to theCAS in column 9702. Referring to FIGS. 85 and 89, the 1stclamps “extend”request 9710 corresponds to extend request 9031 in CA logicspecification 9002. Similarly, the 1stclamps “retract” request 9711corresponds to retract request 9033 in CA logic specification 9002.

Diagram 9706 is temporally spaced along a horizontal axis and includes aseparate bar for each request in column 9704. For example the barcorresponding to 1stclamps extend request 9710 is bar 9712. The bars aresequenced from left to right and top to bottom according to the order inwhich the requests associated therewith occur during the manufacturingprocess. For example, in section 9706, the extend request associatedwith bar 9712 occurs after the request associated with bar 9716 and justbefore the request associated with bar 9718 and so on. Hereinafter, tosimplify this explanation, the bars in FIG. 89 will be referred togenerally as requests.

By selecting and parameterizing CA instances to control each mechanicalresource in a manufacturer line and sequencing CA instance requestsusing a control bar chart like the chart illustrated in FIG. 89,virtually all of the controls information which is required to generateexecution code, schematics, HMI code, diagnostics code and simulationtools is completely specified. Thereafter, a compiler is used asexplained below to generate the execution code for simulation and PLCcontrol.

B. General Overview of System

Referring now to FIG. 90, an exemplary system according to the presentinvention includes a plurality of networked components including a CADsystem 9800, a resource editor 9802, an HMI editor 9804, a diagnosticseditor 9806, an enterprise control data base 9810, a compiler 9812, aPLC 9814, a simulator or core modeling system (CMS) 9816, a movie module9818, an HMI work station 8437, a simulation screen 9820 and a printer8436. System 8458 represents all of the mechanical control mechanismswhich are to be controlled by PLC 9814. Hereinafter, each of thecomponents, editors or systems in FIG. 90 will be explained separatelyor, where advantageous, in conjunction with other components.

1. CAD System/Movie Module

Referring still to FIG. 90, it is contemplated that CAD system 9800 hasa plurality of capabilities. First, CAD system 9800 is useable to definethree dimensional mechanical resources such as clamps, robots, mills,and so on. Second, CAD system 9800 is able to define model movements andmovement ranges and limits.

These two capabilities, to define 3D mechanical resources and theirranges of motion, enable a process engineer to envision a controlsprocess. In addition, in at least one embodiment these two abilities canbe combined with simulation specifications to virtually simulate amanufacturing process.

Third, CAD system 9800 can be used by an engineer to label specificmodel movements or cycles with mechanical resource activity names.Fourth, CAD system 9800 provides tools which allow an engineer tosequence the named activities. Preferably the sequencing is providedusing a mechanical resource timing diagram, a tool which is already wellknown within the controls industry.

Movie module 9818 includes exemplary video clips or motion pictures ofmechanical resources traversing through each possible mechanicalresource activity required during a manufacturing process. For example,in the case of a clamp, the video clips include extend and retract clipscorresponding to clamp videos showing extend and retract movements. Theclips also include stationary clips showing corresponding staticmechanical resources. Video module 9818 is capable of playing aplurality of video clips simultaneously and arranged on a display in amanner which reflects actual layout and configured relationships ofmechanical resources. Module 9818 is linked to screen 9820 for thispurpose. Module 9818 receives command signals from simulator 9816indicating clips to play. Module 9818 is also capable of recognizingspecific occurrences in video clips and providing feedback signals toPLC 9814 via CMS 9816 for simulation purposes.

At this point, it will be assumed that CAD system 9800 has already beenused to define all mechanical resources to be used in an exemplarymanufacturing process, mechanical resource activity cycles have beengiven activity names and a mechanical timing diagram has been providedwhich is stored in database 9810.

Referring now to FIG. 91, a portion of an exemplary mechanical resourcetiming diagram 9650 is illustrated. Diagram 9650 includes a mechanicalresource column 9652, an activities column 9654 and a timing diagram9656. Resource column 9652 lists all of the mechanical resources which aprocess engineer has specified for an exemplary manufacturing process inthe order in which corresponding mechanical resource activities willoccur. Although not illustrated, most of the mechanical resources willbe listed more than once in resource column 9652 as most mechanicalresources perform more than a single activity during a manufacturingprocess. For example, a clamp will typically extend and retract at leastonce during a manufacturing process and therefore would appear at leastonce for an extend activity and at least a second time for a retractactivity.

The activity column 9654 includes a list of activities corresponding tothe mechanical resources of column 9652. For example, with respect to aclamp 9651, a specified activity 9653 is “Fixture” meaning that theclamp 9651 should fix or close or extend onto a work item. Similarly, aplurality of other clamps are to extend along with clamp 9651, the otherclamps including, among others, clamps 9655, 9657 and 9659.

Timing diagram 9456 is temporarily spaced along a horizontal axis andincludes a plurality of bars which are arranged in sequential order fromleft to right and top to bottom, a separate bar corresponding to each ofthe activities in column 9654. Thus, bars 9658 through 9660 indicatefixture of three pins (i.e., mechanical resources), bar 9661 indicates aloading activity by a robot gripper, bar 9663 indicates fixture of adump 9665, bar 9662 indicates fixture of clamp 9651, and so on. Clamp9651 does not begin to close until after dump 9665 fixture is completeand clamp 9651 must be closed before an operator loader 9666 can load(i.e., perform the specified activity 9668).

With a complete mechanical timing diagram specified, the inventiveresource editor and other editors can now be described.

2. Editors

Referring to FIG. 90, the present invention includes resource editor9802 and is meant to be used with both HMI editor 9804 and a diagnosticseditor 9806. Each of the resource, HMI and diagnostics editors aredescribed separately.

a. Resource Editor

Referring still to FIG. 90, resource editor 9802, as well as all of theother editors 9804, 9806 used with the present invention, preferably, isprovided via software which runs on a work station or the like, enablinga control engineer to use display screen tools such as tables, windowsand work spaces and a mouse-controlled icon for selecting variousbuttons and pull-down menus to specify controls information with the aidof a CA template library which is stored in ECDB 9810.

To this end, referring to FIG. 55, an exemplary resource editor imagewhich may be displayed on a work station display screen is illustrated.Hereinafter resource editor 9802 is often referred to as a designerstudio. Screen 5500 includes a tool bar 5502 and four work spacewindows. The work space windows include a mechanical resources window5504, a mechanical timing diagram window 5506, a control resourceswindow 5508 and a control bar chart window 5510. Tool bar 5502 includesediting tools which will be described in more detail below throughexemplary use. When a mechanical timing diagram is imported into theresource editor environment, the mechanical timing diagram is presentedwithin mechanical timing diagram window 5506 and each mechanicalresource within the diagram is provided within a list inside themechanical resources window 5504.

Initially, it will be assumed that a plurality of differentmanufacturing processes have been defined using CAD system 9800 and thata separate mechanical timing diagram corresponding to each one of thedefined manufacturing processes is stored in data base 9810. Referringnow to FIG. 57, a mouse-controlled cursor (not illustrated) can be usedalong with the tool bar 5502 to select one of the stored mechanicalresource timing diagrams by selecting the manufacturing process name5512 from a list. Referring also to FIG. 58, once a mechanical timingdiagram has been selected, the mechanical timing diagram is importedinto window 5506, and the list of mechanical resources is provided inwindow 5504. The mechanical timing diagram in this case is identified by5820 while the mechanical resource list is identified by 5810.

Referring to FIGS. 58 and 91, it should be appreciated that themechanical timing diagram 5820 is identical to the diagram 9650. Itshould also be recognized that only a small portion of the mechanicaltiming diagram is illustrated in window 5506, the diagram extending tothe right and downward further than window 5506 will allow. In addition,diagram 5520 includes a key 5514 above the timing diagram section. Key5514 indicates differently shaded bars corresponding to different typesof resources. A dark bar 5516 corresponds to a mechanical activity, adarkly shaded bar 5518 corresponds to a robot activity (an activity forwhich additional programming is required) and a lightly shaded bar 5520corresponds to an activity which must be performed by a human operator.

In addition, when a mechanical timing diagram is imported into theresource editor environment, resource editor 9802 assumes that a controlsystem is to be defined for controlling the mechanical resources in thetiming diagram. Therefore, resource editor 9802 automatically provides alist 5512 of control assemblies in control resources window 5508, thelist 5512 including all possible control assemblies which may be used tocontrol mechanical resources in diagram 5820. Of particular interest inexplaining operation and features of the present invention, note thatone of the CAS in list 5512 is a “safe bulk head clamp set” CA 5540, CA5540 corresponding to the clamp template described in detail above.

Moreover, resource editor 9802 automatically constructs an initial andblank control bar chart image 5830 within control bar chart window 5510.Referring to FIGS. 58 and 89, image 5830, like control bar chart 9700,includes a control assembly column 5522, a requests column 5524 and abar chart diagram 5526. While blank diagram 5526 does include a timinggrid which is initially identical to the grid of mechanical timingdiagram 5820 including identical spaced edges (e.g. 5523, 5527, etc.)and period durations which is helpful for subsequent sequencing of CArequests. In addition, editor 9802 provides a key 5528 above bar chartdiagram 5526. Key 5528 specifies four differently shaded barscorresponding to characteristics of associated requests. A black bar5530 indicates a physical request (i.e. typically a mechanicaloperation), a bar having a first shading characteristic 5532 indicates aprogrammable request (i.e. typically a request to a robot), a bar havinga second shading characteristic 5534 indicates a virtual request (i.e. arequest which is performed by an entity which is not controlled by thecontrol system such as a human operator) and a bar having a thirdshading characteristic 5536 indicating a conditional (i.e. acharacteristic which must be met prior to other requests occurringthereafter.) Referring now to FIG. 59, to begin specifying CAS forcontrolling the mechanical resources in timing diagram 5820, a controlengineer selects an add icon 5542 from tool bar 5502 which opens a pulldown window with a single option 5544 entitled “control assembly.”Referring to FIG. 60, when option 5544 is selected, a window menu 5546opens up which includes a control assembly type list 5548, a “new” icon5550 and a “cancel” icon 5552. The CA types in list 5548 include each ofthe CAS in list 5512 including “safe bulk head clamp set type” 5554. Theengineer may select any CA type from list 5548. In the present example,it is assumed that, initially, the engineer wishes to select a CA forcontrolling four clamps which move simultaneously during the mechanicalprocedure specified by timing diagram 5830. To this end, the engineerselects the “safe bulk head clamp set” type 5554 and thereafter selectsthe new icon 5550 indicating that a new CA instance is being specified.

When the “safe bulk head clamp set” type 5554 is selected, although notillustrated and observable by a system user, resource editor 9802automatically identifies every mechanical resource within mechanicalresource window 5504 which could possible be controlled via an instanceof the “safe bulk head clamp set” CA and stores the list of mechanicalresources in ECDB 9810 (see FIG. 90). The controllable mechanicalresource list is subsequently provided to the system user to help thesystem user identify mechanical resources to be controlled by thespecific CA instance as will be explained in more detail below withrespect to FIGS. 64 and 65.

Referring to FIG. 61, when new icon 5550 is selected, an instructionswindow 5556 opens which helps guide the engineer through use of resourceeditor 9802. To this end, window 5556 indicates that a name must bespecified for the specific CA instance being created or instantiated,the resources that will be controlled by the CA must be specified and,for control devices in the CA which have a variable number, the numberof control devices to be included in the CA must be specified.

When a “next” icon 5558 is selected, referring to FIG. 62, a window 5562opens up which includes a name field 5564 for specifying a name for thespecific instance of the “safe bulk head clamp set” CA beinginstantiated. The engineer specifies the name in window 5564. Inaddition, window 5562 includes a plurality of different options andcorresponding flag boxes for selecting those options for the CA. Theoptions include specifying an HMI for the assembly 5566, specifyingsimulation tools for the assembly 5568, creating a wiring diagram forthe assembly 5570, creating diagnostics for the assembly 5572 andcreating documentation for the assembly 5574.

Flag boxes corresponding to the options 5560 through 5574 are identifiedgenerally by numeral 5576. When a flag appears in one of flag boxes5576, the function associated therewith is requested. Initially it isassumed that each of flag boxes 5576 includes a flag so that, initially,each of the options 5560 through 5574 is initially selected.

To deselect one of the functions, the mouse controlled cursor ispositioned within a particular flag box 5576 and a mouse selectionbutton is activated at which point the flag is removed from the box.Once the flags in boxes 5576 have been set as desired and a name hasbeen provided in box 5564, “next” icon 5558 is again selected.

As illustrated in FIG. 63, in the present example, the CA instance name5578 provided in box 5564 is “1stclamps”. When “next” icon 5558 isselected, referring to 64, another window 5580 is provided whichincludes a mechanical resource list window 5582 and a selected resourcelist window 5584 along with “add” and “delete” icons 5586 and 5588,respectively.

As indicated above with respect to FIG. 60, when the“SafeBulkHeadClampSet” CA type was selected (see FIG. 60), resourceeditor 9802 automatically accessed the mechanical resource list inwindow 5504 and identified each mechanical resource in window 5504 whichcould possibly be controlled via the selected CA type. For example, inthe present case, because the “SafeBulkHeadClampSet” CA type 5554 wasselected, editor 9802 searched the resource list in window 5504 andidentified every clamp within window 5504 to form a list of possiblemechanical resources to be controlled by the particular instance of the“safe bulk head clamps set” CA. The list of clamps controllable by thefirst clamps control assembly is provided in mechanical resource listwindow 5582. Initially, selected resource list 5584 is blank.

To select clamps from the list in window 5582 to be added to theselected resource list window 5584, an engineer uses a mouse controlledcursor to highlight one or more of the clamps in list 5582 and thenselects “add” icon 5586. In the present example it is assumed that a CAis only capable of controlling a maximum of four clamps at one time.Thus, referring to FIG. 65, after four clamps 5590, 5592, 5594 and 5596have been added to list window 5584, no more clamps can be added. Toremove a clamp from window 5584 and hence deselect the clamp, the clampis highlighted in window 5584 and the “delete” icon 5588 is selected.

Referring now to FIGS. 65 and 85, each time a clamp is added to list5584, a flag is provided in another one of flag boxes 9482 a, 9484 a or9486 a to select an additional set of cylindicator logic forinstantiation in the CA logic specification 9002. In addition, a clampindicator name indicating a specific clamp associated with thecylindicator logic is provided. For example, 1st cylindicator 9425 islabeled “clamp 2506A”, 2nd cylindicator 9427 is labeled “clamp 4502” andso on. Therefore, at the end of adding each of clamps 5590, 5592, 5594and 5596 to list 5584, four distinct sets of cylindicator logiccorresponding to cylindicators 9425, 9427, 9429 and 9431 areinstantiated in logic specification 9002.

Referring to FIGS. 85 and 85A, when a flag is provided in one of boxes9482 a, 9484 a or 9486 a, a flag is also provided in a correspondingselection box 9482 f, 9484 f and 9486 f, respectively. Flags in boxes9482 f, 9484 f and 9486 f indicate that corresponding cylindicators9427, 9429 and 9431, respectively, will be represented in a compiledschematic.

In addition, referring to FIGS. 65, 85 and 86, each time a clamp isadded to list 5584 so that a flag is provided in one of boxes 9482 a,9484 a or 9486 a, a flag is also provided in a corresponding flag box9482 b, 9484 b or 9486 b, respectively. These flags indicate thatadditional monitorable I/O and controllable outputs/requestscorresponding to the second through fourth cylindicators 9427, 9429 and9431, respectively, should be designated for presentation duringsubsequent HMI feature selection using the HMI editor 9804 describedbelow.

Moreover, referring to FIGS. 65, 85 and 87, each time a flag is providedin one of boxes 9482 a, 9484 a or 9486 a, a flag is provided in a flagbox 9482 c, 9484 c or 9486 c corresponding to an associated cylindicatorlisted in column 9602. The flags in column 9602 indicate that additionaldiagnostics corresponding to each of the flag cylindicators isdesignated for presentation during subsequent diagnostics featureselection using the diagnosis editor 9806 described below.

Furthermore, referring to FIGS. 65 and 88, each time a clamp is added tolist 5584 so that a flag is provided in one of boxes 9482 a, 9484 a or9486 a, corresponding flags are provided in flag boxes in simulationspecification 9300. For example, if a flag is placed in box 9482 acorresponding to second cylindicator 9427, corresponding flags areplaced in boxes 9482 d and 9482 e which likewise correspond to secondcylindicator 9427. Flags in boxes 9482 d and 9482 e indicateinstantiation of the information in tables 9303 and 9305 for subsequentcompilation.

In addition, when a table in specification 9300 is instantiated, thename mechanical resource to be controlled by a cylindicatorcorresponding to the table is added to the table. For example, resourcename “clamp 2506A” is added to tables 9302 and 9304 corresponding to 1stcylindicator 9425 which will control clamp 2506A, resource name “clamp4502” is added to tables 9303 and 9305 corresponding to 2nd cylindicator9427 which will control clamp 4502. Similarly, resource namescorresponding to clamps 5508B and 5509A are provided for 3rd and 4thcylindicator tables like tables 9302 and 9304.

Referring to FIGS. 65 and 66, after clamps 5590, 5592, 5594 and 5596have been added to list 5584, the control engineer may select “next”icon 5558 which opens a 1stclamps summary window 5607. Summary window5607 includes a summary table 5609 including a label column 5611, acontrol component column 5613, a type column 5615 and a function column5617. Label column 5611 lists each of the mechanical resources which areto be controlled by the “1stclamps” CA and therefore includes clamps5590, 5592, 5594 and 5596.

Control component column 5613 lists all of the control components orcontrol mechanisms which are controlled by the “1stclamps” CA andcorrelates control components with mechanical resources in column 5611.To this end, a separate air cylinder is correlated with each of clamps5590, 5592, 5594 and 5596. In addition, air valves 5619 and 5621corresponding to the two position valve 9421 and the spring return valve9423 (see FIG. 85) are also provided in column 5613.

Type column 5615 lists control mechanism types corresponding to each ofthe control components in column 5613 and, to this end, lists a doublesolenoid corresponding to air valve 5619, a single solenoidcorresponding to air valve 5621 and separate cylindicators correspondingto each of the air cylinders in column 5613.

Function column 5617 lists the function of each of the controlcomponents in column 5613. To this end, column 5617 indicates that airvalve 5619 provides main control for the “1stclamps” CA, that air valve5621 is a safety valve and that each of the air cylinders in column 5613is provided as an air-motion converter. Thus, table 5609 simplysummarizes the various control components, their types and functionswhich have already been specified with respect to the “1stclamps” CA.

To further parameterize the “1stclamps” CA, the control engineer mayselect “edit” icon 5623. Referring to FIGS. 66 and 85, when “edit” icon5623 is selected, an editing window 5625 is opened which enables thecontrol engineer to further parameterize the “1stclamps” CA. To thisend, window 5625 essentially displays all of the logic in the“1stclamps” CA logic specification 9002 including each of the controldevices (i.e. two position valve 9421, spring return valve 9423, andfirst through fourth cylindicators 9425, 9427, 9429 and 9431), each oftheir inputs and outputs, the extend logic and retract logic charts andproperties sections 9036 and 9066. Various types of parameterization canbe performed using window 5625 and a mouse controlled cursor. To thisend, using the mouse controlled cursor, an engineer can modify any ofthe latch, restart, or inverse request properties in properties sections9036 and 9066 by either placing flags in flag boxes 9051, 9053, etc., orremoving flags from those boxes. In addition, the control engineer canselect or deselect any of the spring return valve 9423, cylindicator9427, cylindicator 9429, or cylindicator 9431 by placing flags in orremoving flags from boxes 9480 a, 9482 a, 9484 a or 9486 a,respectively. As indicated above, flag manipulation in boxes 9480 a,9482 a, 9484 a and 9486 a ripples through other CA specifications (seeFIGS. 85A, 86, 87 and 88). Referring still to FIG. 85, after propertieswithin sections 9036 and 9066 have been set as desired and the controldevices have been selected as desired, the control engineer may selectthe “back” icon 5631 to return to summary window 5607 illustrated inFIG. 66. Although not illustrated, when the engineer returns to window5607, if the spring return valve 9423 has been deselected, air cylinder5621 and other information within table 5609 corresponding thereto willnot appear within table 5609 or, may appear in a form which isrecognizable as a form indicating a deselected control component andcorresponding information (i.e. air valve 5621 and informationcorresponding thereto may be highlighted in some manner). Hereinafter itwill be assumed that the control engineer does not de-select valve 9423and therefore valve 9423 remains instantiated in the 1stclamps CAinstance. Referring to FIG. 66, to continue, the control engineerselects “next” icon 5558 which opens a completed assembly summary window5633 illustrated in FIG. 67. Window 5633 specifies the new controlassembly type as a “SafeBulkHeadClampSet” 5635 type, the instance ofwhich is named “1stclamps” 5637. In addition, window 5633 also providesinformation about the CA instance author, the date of instantiation, andother useful information corresponding to the “1stclamps” CA.

Referring to FIGS. 67 and 92, after confirming the correctness of all ofthe information in window 5633, the control engineer selects “next” icon5558 which opens a sequencing window 5651. Window 5651 providesinstructions to the engineer indicating that the engineer may eithermanually sequence 1stclamps CA instance requests or, in the alternative,may allow the resource editor 9802 to automatically sequence the1stclamps requests. To this end, editor 9802 provides an icon for eachpossible 1stclamps CA request and an “automatic” icon 5657. Referringagain to FIG. 85, because the 1stclamps CA only includes extend andretract requests 9031, 9033, respectively, editor 9802 provides an“extend” icon 5653 and a “retract” icon 5655 within window 5651.

To manually place the “1stclamps” “extend” request within the controlbar chart in window 5510, the control engineer selects “extend” icon5653. Referring also to FIG. 59, after selecting “extend” icon 5653, thecontrol engineer uses a mouse controlled cursor to select either a spaceor an edge within bar chart 5830 for placement of the extend request. InFIG. 59, exemplary edges are identified by numerals 5529 and 5527 whichdefine an empty space 5531 therebetween. In the present example, it willbe assumed that the engineer selects space 5531 by placing the cursortherein and activating a mouse selection button. When space 5531 isselected, referring also to FIG. 69, editor 9802 places a black barwithin space 5531, identifies 1stclamps in control assembly column 5522and identifies extend request 7001 in the request column 5524. A similarmanual operation can be performed to place the 1stclamps retract requestin bar chart 5830, a black bar corresponding thereto placed in space5671 is illustrated in FIG. 70. In the alternative, referring again toFIGS. 90 and 92, by selecting “automatic” icon 5657, the controlengineer causes resource editor 9802 to automatically sequence both the1stclamps “extend” and “retract” requests. To this end, when “automatic”icon 5657 is selected, referring also to FIG. 70, editor 9802automatically sequences the 1stclamps “extend” request with the periodin mechanical timing diagram 5820 corresponding to extension of theclamps 5590, 5592, 5594 and 5596 in the 1stclamps CA. To this end, theclamp extension period is identified in mechanical timing diagram 5820as period 5673. Therefore, because space 5531 corresponds to period5673, editor 9802 automatically places a bar within space 5531,identifies 1stclamps in column 5522 and identifies “extend” request incolumn 5524. Similarly, editor 9802 automatically places the 1stclampsretract request in space 5671 corresponding to the period 5675 duringwhich the clamps 5590, 5592, 5594 and 5596 associated with the 1stclampsCA retract.

Initially, it may appear as though manual sequencing of requests is notnecessary and that an engineer should always allow resource editor 9802to automatically sequence CA requests. While this may be true for simpledevices such as a clamp or a pin locator, many other mechanicalresources are much more complex and may perform separate requests duringa complete manufacturing process, some of which are not reflected in themechanical timing diagram 5820. For example, in the case of an exemplaryrobot, many robots are programmed to perform housekeeping requests atthe beginning of each new manufacturing cycle (a manufacturing cyclecorresponding to a single pass through mechanical timing diagram 5820).In this case, while the exemplary robot may perform a single “forward”request during a fifth mechanical timing diagram period and may performa “reverse” request during a twelfth mechanical timing diagram period,it may be necessary for the robot to perform housekeepingfunctions/requests prior to the first period in the mechanical timingdiagram 5820. In the alternative, it may be necessary for the robot toperform the housekeeping requests at some other time (e.g. between thethird and fourth diagram periods) or more than once during amanufacturing cycle. In this case, the robot requests to be sequencedwould include a housekeeping request, a “forward” request and a“reverse” request. While resource editor 9802 may be able toautomatically place the forward and reverse requests as a function ofthe sequencing of similar activities in mechanical timing diagram 5820,editor 9802 would have no way of determining where to sequence thehousekeeping request. Although not described here in detail othercircumstances requiring manual placement of requests do occur.

Referring once again to FIG. 69, after the 1stclamps “extend” and“retract” requests have been placed within diagram 5830, the “1stclamps”CA instance of the “SafeBulkHeadClampSet” template type is identifiedwithin control resources window 5508 as “1stclamps” 6910 in a hierarchalfashion and the “extend” and “retract” requests are placed under1stclamps 6910 as requests 6911 and 6913, respectively.

Referring now to FIG. 71, after the 1stclamps “extend” and “retract”requests have been sequenced within diagram 5830, the control engineeragain access window 5546 to select another control assembly type fromlist 5548 for controlling additional mechanical resources in diagram5820. The process described above is repeated until CA instances havebeen instantiated (i.e. specified, parameterized and sequenced) forevery mechanical resource in diagram 5820. An exemplary completedcontrol bar chart 5830 is illustrated in FIG. 72.

Referring to FIGS. 72 and 92, after CA sequencing the control engineeragain selects “next” icon 5558 which, as illustrated in FIG. 93, opensup a contingencies window 5681. Window 5681 includes a list 5683 ofcontingencies 5685, 5687, . . . 5689 upon which a request may be madecontingent. Generally, resource editor 9802 generates contingency list5683 by gleaning the “done” I/O combinations corresponding to every CArequest for every CA included in list 5522 (see FIG. 72). For example,referring also to FIG. 85, the done condition 5691 corresponding to the1stclamps extend request 9031 requires active solenoid outputs O1, O2,O5 and O6, passive solenoid outputs O3 and O4, active proximity sensorinputs I1, I3, I5 and I7 and passive proximity sensor inputs I2, I4, I6and I8. Other contingencies, in addition to done I/O combinations mayalso be specified within list 5683. For example, referring again to FIG.85, another exemplary contingency may simply require that outputs O1 andO2 be active and may be independent of the condition of other outputsand cylindicator inputs in the 1stclamps CA instance which contingenciesare provided in list 5683 is a matter of CA designer choice.

Referring to FIGS. 93 and 94 after a contingency from list 5683 has beenselected, a second contingencies window 5695 opens. In the presentexample, it is assumed that the second contingency 5687 has beenselected from list 5683 and therefore, the second contingency 5687 isindicated in window 5695. In addition, editor 9802 provides an“interlock” icon 5697 and a “safety” icon 5699 adjacent contingency 5687in window 5695.

On one hand an interlock is a contingency which must be met and mustexist at the beginning of a request subject thereto but need notcontinue to exist during performance of the request. For example, aninterlock may require that a clamp be parked in a retracted positionprior to a transfer bar moving a work piece adjacent thereto. After thetransfer bar begins to move, continued transfer bar movement does notrequired that the clamp remain parked. On the other hand a safety is acontingency which must exist at the beginning of, and must continue toexist during the course of, a request which is subject thereto. Forexample, if a parked clamp is a safety linked to transfer bar movement,as a transfer bar moves, if the clamp is moved, the transfer bar isimmediately stopped.

Referring again to FIG. 93, any of the contingencies in list 5683 may belabeled as either an interlock or a safety. Referring also to FIGS. 94and 72, assuming “interlock” icon 5697 is selected, editor 9802 providesbar chart 5830 as illustrated and allows the control engineer to selectany edge (e.g. 5529, 5527, etc.) by placing a mouse controlled cursor onthe edge and activating a mouse selection button. For example if thesecond contingency corresponds to a parked transfer bar and the controlengineer wishes to make the 1stclamps “extend” request 5701 contingentupon the transfer bar being parked, the control engineer may select edge5529.

Referring still to FIG. 72, when an edge is selected for placement of aninterlock or a safety, preferably some contingency indication is addedto control bar chart 5830. To this end, in the present example, a“yield” icon 5703 is provided at the top of bar chart 5830 which islinked to the selected edge 5529. It is contemplated that, if icon 5703is selected by an engineer, editor 9802 will open another window (notillustrated) which will specify the nature of the interlock associatedwith the corresponding edge.

Referring to FIGS. 72 and 94, by selecting “safety” icon 5699, aprocedure similar to the procedure described above for selecting an edgefor an interlock is used to select an edge for the safety. In FIG. 72 itis assumed that edge 5705 is selected for the safety. In this case,instead of providing a “yield” icon 5703, where a safety is associatedwith an edge, a “stop” icon 5707 is provided which is linked to theselected edge (see 5705). Once again, if an engineer selects icon 5707,editor 9802 opens a window (not illustrated) which specifies the natureof the safety associated with the corresponding edge.

Referring still to FIG. 72, while only a single interlock contingency5703 and a single safety contingency 5707 are illustrated, manydifferent contingencies may be added to bar chart 5830. In addition, itis contemplated that more than a single interlock or safety or, indeed,both interlocks and safeties may be linked to a single edge. Where bothinterlocks and safeties are linked to a single edge, editor 9802provides both a “yield” icon and a “stop” icon above the correspondingedge. In addition, is should be appreciated that other way to indicateinterlocks and safeties and specifying interlocks and safeties arecontemplated by the present invention and that the present inventionshould not be limited by the description included herewith. For example,another way to indicate interlocks and safeties may be to provide acomment directly on bar chart 5830 which comprises text in a conditionalhorizontal space where the edge occurs.

b. HMI Editor

In addition to the logic and sequencing described above in the contextof resource editor 9802, it is also necessary to specify features ofeach sequenced CA which are to be monitored and controlled via an HMI.For example, referring again to FIG. 86, with respect to the 1stclampsCA described above, while virtually all 1stclamps I/O may possibly bemonitored and all 1stclamps outputs and extend and retract requests9031, 9033 may be controllable, it is unlikely that a control engineeror a system operator would require or desire such extensive monitoringand control capabilities. Instead, in the context of the 1stclampsexample, it is more likely that a system operator would only require ordesire a sub-set of the I/O to be monitored and would only require asub-set of the outputs and possible requests to be controllable. In thepresent example it will be assumed that the operator only requirescontrols for separately controlling the “extend” and “retract” requestsand monitorable indicators to indicate the active/passive status of thefirst cylindicator 9425 inputs I1 and I2.

To this end, referring to FIG. 95, an exemplary HMI screen 7003 suitablefor controlling and monitoring the 1stclamps CA in the manner indicatedabove is illustrated. Screen 7003 is divided into an HMI section 7005and a diagnostic section 7007. HMI section, 7005 is divided intoseparate control sections 7009, 7011, 7013 and 7015. Diagnostic section7007 is described in more detail below.

Referring also to FIG. 72, it is contemplated that HMI section 7005 maypotentially include a separate controls section for each controlassembly listed in control assembly column 5522. In the alternative, acontrol system may include a plurality of controls screens, a separatescreen for controlling and monitoring each control assembly in column5522 or to separate screens for controlling distinct sub-sets of thecontrol assemblies is column 5522. In FIG. 95, only four controlsections 7009, 7011, 7013 and 7015 are illustrated, the control sections7009, 7011, 7013 and 7015 corresponding to the above described 1stclampsCA and 2nd, 3rd and 4th clamps CAS, respectively. Only control section7009 is shown with some detail, sections 7011, 7013 and 7015 abbreviatedto simplify the present explanation. Nevertheless, it should beunderstood that each of sections 7011, 7013 and 7015 and additionalcontrol sections (not illustrated) corresponding to other CA instanceswould include control tools and monitoring indicators of various typesand configurations.

Referring still to FIG. 95, exemplary control section 7009 includes anindication 7017 of the CA instance (i.e. 1stclamps) which iscontrollable and monitorable via section 7009 and also includes controltools and monitoring indicators corresponding to the 1stclamps CA. Tothis end, the exemplary control section 7009 includes a virtual “extend”button icon 7019 and a virtual “retract” button icon 7021. It iscontemplated that a mouse controlled cursor (not illustrated) can beused by a system operator to select either of icons 7019 or 7021 tocause the control mechanisms associated with the 1stclamps CA to forcecorresponding clamps into the extended and retracted positions,respectively. In the alternative, where a system is equipped with touchscreen HMI's, each of icons 7014 and 7021 is selectable via touch.

In addition to icons 7019 and 7021, control section 7009 also provides arepresentation of each 1stclamps control device for which I/O is to bemonitored. In the present example, referring again to FIG. 86 and alsoto FIG. 95, because it has been assumed that inputs I1 and I2corresponding to the first cylindicator 9425 are to be monitored, thefirst cylindicator 9425 is identified in section 7009. Moreover,monitoring indicators, 7023 and 7025 are provided for first cylindicator9425. Indicators 7023 and 7025 indicate extended and retracted firstcylindicator conditions. Thus, extended and retracted 1st cylindicatorlabels are provided adjacent indicators 7023 and 7025, respectively.

It should be appreciated that while one configuration for an HMI isdescribed above and with respect to FIG. 95, other HMI configurationsare contemplated by the present invention and the invention should notbe limited by the described configuration. To this end, it iscontemplated that each CA is simply used to indicate I/O to be monitoredand controlled and that the compiler 9812 (see FIG. 90) includes rulesfor specifying HMI configuration based on CA specified I/O which must besupported by an HMI.

In addition, referring again to FIG. 90 while the HMI editor 9804 couldbe entirely separate from resource editor 9802 and could be used aftersequenced CAS have been compiled, in the present example, HMI editor9804 will be described as an editor which can be used in a seamlessmanner to move from using resource editor 9802 to HMI tools forspecifying I/O to be monitored and controlled. To this end, referringonce again to FIG. 94, after all interlocks and safeties have beenspecified for sequenced CAS, the control engineer selects “next” icon5558 once again. When icon 5558 is again selected, referring to FIG. 96,resource editor 9802 provides a window 7027 enabling the engineer tospecify either HMI or diagnostics information. Window 7027 includes an“HMI” icon 7029 and a “diagnostics” icon 7031. By selecting“diagnostics” icon 7031 the engineer enters the diagnostics editor 9806described in more detail below.

Referring to FIGS. 96 and 97, when “HMI” icon 7029 is selected, controlis shifted to HMI editor 9804 which provides a first HMI editor screen7033. Referring also to FIG. 72, list 7035 includes all of the CAinstances grouped by CA type which appear in control resources window5508. Thus, the 1stclamps CA instance 7037 appears along with the 2ndclamps, 3rd clamps and 4th clamps instances under the CA type“SafeBulkHeadClampSet” 7039 in list 7035. Once again a mouse controlledcursor (not illustrated) is used by the control engineer to select oneof the CA instances at a time for identifying I/O to be monitored andcontrolled via an HMI to be subsequently configured by compiler 9812(see FIG. 90).

Referring to FIGS. 97 and 98, when the control engineer selects the1stclamps instance 7037, editor 9804 provides a second HMI screen 7041.Referring also to FIG. 86, it should be appreciated that the informationprovided on screen 7041 is similar to the information stored in HMItable 9460 including a device column 7043, a monitorable I/O column 7045and a controllable outputs/requests column 7047.

While the information provided on screen 7041 appears similar to theinformation in table 9460, there are a number of important distinctions.First, referring to FIGS. 86 and 95, the information provided on screen7041 reflects only required and selected control devices andcorresponding monitorable and controllable I/O from table 9460. In thepresent example, both two position valve 9421 and cylindicators 9425 arerequired and therefore appear on screen 7041. Spring return valve 9423has remained selected and each of the second through fourthcylindicators 9427, 9429 and 9431 have been selected and therefore eachof those devices also appear in table 7041. However, if spring returnvalve 9423 had been de-selected (i.e. via box 9480 a in FIG. 85), springreturn valve 9423 and corresponding monitorable and controllable I/Owould not appear on screen 7041. Similarly, if one or more of thesecond, third or fourth cylindicators 9427, 9429 or 9431 had not beenselected (i.e. via boxes 9482 a, 9484 a and 9486 a in FIG. 85), thecylindicator(s) not selected and corresponding monitorable andcontrollable would not appear on screen 7041.

Second, at this point it is contemplated that the control devices forthe 1stclamps CA instance have already been selected using resourceeditor 9802 and therefore, cannot be selected or de-selected using theHMI editor 9804. Therefore, while flag boxes 9480 b, 9482 b, 9484 b and9486 b appear in table 9460, none of those boxes appear adjacent devicerepresentations in column 7043.

Referring still to FIG. 98, initially flag boxes (e.g. 7049, 7051, etc.)corresponding to monitorable and controllable I/O and requests incolumns 7045 and 7047 are blank (i.e. do not include flags). It iscontemplated that any of the flag boxes may be selected via a mousecontrolled cursor by selecting the box and activating an activationbutton on the mouse. In the present example, it is assumed that thecontrol engineer would like to provide control tools for controllingeach of the extend and retract requests and would like to providemonitorably indicators for each of the first cylindicator 9425 inputs I1and I2 (e.g. see exemplary HMI screen in FIG. 95.) To specifymonitorably and controllable I/O, the control engineer uses the mousecontrolled cursor to place flags in boxes 7053 and 7055 corresponding toinputs I1 and I2, respectively, and to place flags in boxes 7057 and7059 corresponding to extend and retract requests, respectively. Theseflags are illustrated in FIG. 98. To specify other I/O to bemonitored/controlled the engineer places additional flags in boxes. Tode-select a selected I/O, the engineer simply re-selects thecorresponding box to remove the flag.

Referring to FIGS. 86 and 98, when flags are placed in boxes 7053, 7055,7057 and 7059, editor 9804 provides corresponding flags in boxes 9493,9495, 9490 and 9492, respectively. Thus, HMI editor 9804, includingscreens 7033 (see FIG. 97) and 7041 (see FIG. 98), is used to select asub-set of the monitorable and controllable I/O and requestscorresponding to designated control devices. The selected I/O andrequests are indicated in table 9460 and later used during compilationto provide execution code to support the HMI and to generate a HMIprogram to support the HMI tools/indicators, etc.

In addition, when a flag is placed in any of the boxes in column 7047indicating manual control, a flag is automatically placed in a manualselection box 9051 indicating that a control tool for selecting manualsystem operation must be provided on a final HMI.

When the control engineer is finished setting the flags on screen 7041corresponding to the 1stclamps CA instance, the engineer selects the“finish” icon 7061 which again brings up the HMI editor screen 7033 (seeFIG. 97). Next, the engineer may select any of the other CA instances inlist 7035 for selecting monitorable and controllable I/O in the mannerdescribed above. When another CA instance is selected from list 7035,another HMI editor screen similar to screen 7041 (see FIG. 98) isdisplayed which includes monitorable and controllable I/O specified bythe CA instance and which can be selected via flags to be supported by asubsequently compiled execution code.

Referring to FIGS. 96 and 97, after the control engineer has set all ofthe flags corresponding to monitorable and controllable I/O which haveto be supported by an HMI and corresponding execution code, the engineerselects “finish” icon 7061 to return to window 7027. At this point, HMIspecification is complete.

c. Diagnostics Editor

Referring again to FIG. 87, while diagnostic specification tables liketable 9600 designate a large number of diagnostic conditions andassociated activities for CAS sequenced via resource editor 9802, as inthe case of the HMI specification (see FIG. 86), often a controlengineer will only require a sub-set of possible diagnosticcapabilities. Thus, referring to FIGS. 87 and 90, diagnostics editor9806 provides tools which enable a control engineer to select a sub-setof the requirement/activity possibilities in table 9600 to be supportedby a subsequently compiled execution code. Referring also to FIG. 95, inthe present example, while the execution code is running, when adiagnostic condition to be reported occurs, the condition is reported indiagnostics section 7007 as a text phrase.

Referring to FIGS. 96 and 99, a control engineer selects “diagnostics”icon 7031 to specify diagnostics to be supported by the execution code.When icon 7031 is selected, diagnostics editor 9806 provides diagnosticseditor screen 7101. Screen 7101, like HMI editor screen 7033 illustratedin FIG. 97, provides a control assembly instances list 7103 which,referring once again to FIG. 72, lists each control assembly instance,according to control assembly type, from control resources window 5508.Thus, once again, the “first clamps” CA 7105 is listed as an instance ofthe “safe bulkhead clamp set” control assembly type 7107 in list 7103.

Referring still to FIG. 99, using a mouse controlled-cursor (notillustrated), the control engineer selects each of the CA instances fromlist 7103 one at a time for which diagnostics is to specified.Continuing with the present example, referring also to FIG. 100, it isassumed that the engineer selects the “first clamps” CA 7105 at whichpoint diagnostics editor 9806 provides diagnostics editor window 7109.

Referring to FIGS. 87 and 100, window 7109 provides essentially all ofthe information from diagnostic specification table 9600 and thereforeincludes a device/requests column 7111, a requirements column 7113, andan activities column 7115. Each device in the “1stclamps” CA instancefor which diagnostic specification is provided in diagnostics table 9600is listed in device/requests column 7111. Requirements corresponding toeach device in column 7111 are listed in column 7113 and correspondingactivities to be performed if the requirement in column 7113 is met arelisted in column 7115. In addition, selection boxes 7117, 7119, 7121,7123, 7125, and 7127 are provided adjacent each requirementrepresentation in column 7113. Initially, in the present example, it isassumed that each of boxes 7117 through 7127 is blank indicating thatdiagnostics to be supported by execution code are not initiallyselected. However, using a mouse-controlled cursor, a flag may be placedin any of boxes 7117 through 7127, in a sub-set of those boxes, or ineach of those boxes, indicating that the diagnostics corresponding tothe specific device or request and corresponding requirements andactivities should be supported. In FIG. 100, exemplary flags areillustrated in boxes 7117, 7125, and 7127.

Referring still to FIGS. 87 and 100, when a flag is placed in any ofboxes 7117 through 7125, diagnostics editor 9806 places a correspondingflag in a diagnostic specification table box 2001, 2002, 2003, etc.Thus, diagnostics editor 9806 including screens 7101 (see FIG. 99) and7109 (see FIG. 100) which are used to further specify or selectinformation in diagnostics table 9600 which is to be subsequentlycompiled.

When the flags have been selected and deselected as desired on screen7109, the engineer selects “finish” icon 7601 and editor 9806 againprovides screen 7101 illustrated in FIG. 99. Next, the engineer selectsanother CA instance from list 7103 to select diagnostics to be supportedand follows the flag selecting and deselecting procedure described abovefor the newly selected instance. This procedure is repeated for each CAinstance for which diagnostics is to be supported by the execution code.Thereafter, referring still to FIG. 99, the engineer again selects“finish” icon 7601 and is returned to screen 7027 illustrated in FIG.96.

Referring again to FIG. 87A, in the alternative, where CAS includestatus based diagnostic specifications, it is contemplated that, in apreferred embodiment, the diagnostics specification is not edited.Instead, upon compiling, diagnostics specified in each diagnosticsspecification is repeated for each instantiated CA thereby generatingdiagnostics code which is interspersed within execution code and whichindicates the next event to occur. In this manner, the daunting task ofproviding diagnostics code to support status based diagnostics issimplified through automatic code generation.

At this point, all of the information required to generate executioncode for controlling the exemplary manufacturing process and forsupporting both HMI and diagnostics has been specified. In addition, allthe information required to generate schematic diagrams detailing allaspects of a control assembly have also been specified. Moreover, all ofthe information required to support virtual simulation of the exemplarymanufacturing process has been specified. Next, the sequenced bar chartand instantiated CA instances are stored in database 9810 untilcompiled.

Hereinafter, although many bar charts and corresponding CA instances maybe stored in database 9810, to simplify this explanation, it will beassumed that only single bar chart 5830 (see in FIG. 72) andcorresponding CA instances are stored in database 9810.

3. PLC and HMI

Although it may seem logical to explain operation of compiler 9812 next,some general information about PLC 9814 and HMI 8437 is instructive inlaying a foundation for an understanding of how compiler 9812 operates.Specifically, it is instructive to understand the structure of thecontrol products which must be generated via the compilation process tosupport execution code and an HMI. Generally the control productsrequired to support code and an HMI include a parameterized PLC I/Otable, an HMI configuration/linking table and a diagnostics linkingtable.

Referring to FIGS. 90 and 101, PLC 9814 includes a controller 2001 andat least one I/O card 2003. Controller 2001 includes a microprocessor2005 and a memory 2007. Memory 2007 is used to store both an executioncode 2009 and a PLC I/O table 2011. Code 2009 includes an RLL controlprogram for controlling mechanical resources 8438. As well known in thecontrols art, an RLL program includes sequential LL rungs includingcontacts and coils. The contacts represent PLC inputs and the coilsrepresent PLC outputs. When contacts within a rung all close, anassociated rung coil is excited. Thus, PLC inputs (contacts) change thestates of PLC outputs (coils). PLC inputs are associated with mechanicalresource sensors and indicate resource conditions. PLC outputs arelinked to mechanical resource activators or to PLC input contacts tocause resource control or further processing.

I/O table 2011 is a repository for PLC I/O and PLC signals generally.Referring also to FIG. 102, an exemplary parameterized I/O table 2011includes signal column 2015 and a status column 2017. Column 2015 listsall PLC signals. For example, for the 1stclamps CA instance, the signallist includes inputs 1stclamps I1-I8 and outputs 1stclamps 01-06. Forbrevity sake table 2011 is abbreviated. 1stclamps 01, 02 and 06 areidentified by numerals 8037, 8039 and 8043, respectively. 1stclamps I1and I2 are identified by numerals 8049 and 8046, respectively. Column2015 also includes entries “1stclamps extend request” 2137, “1stclampssafety override” 2729, “1stclamps safety 1” 2049, “1stclamps safety 2”2051, “1stclamps interlock 1” 2077, “1stclamps interlock 2” 2079,“1stclamps extend sensor error” 8113, “1stclamps cylinder failure” 8048,“1stclamps extend done” 8727, “manual” 2113, “1stclamps 01 control” 2133and so on. Each signal in column 2015 corresponds to contact and or acoil in execution code 2009.

Status column 2017 includes a list of instantaneous statuses of signalsin column 2015. Exemplary statuses include closed or active which isidentified by a “1” and open or passive which is identified by a “0”.The statuses active and passive correspond to coils while closed andopen correspond to contacts.

Referring still to FIG. 101, I/O card 2003 is linked to controller 2001via a two-way bus 2021. Card 2003 includes a plurality of I/O pins P-1,P-2, etc. Referring also to FIG. 102, each input pin is linked to amechanical resource sensor while each output pin is linked to amechanical resource activator. I/O card 2003 takes parallel input frompins P-1, P-2, etc. and converts the input to serial input signals whichare provided to processor 2005 to update I/O table 2011. Similarly, card2003 receives serial PLC output signals from table 2011 and convertsthose output signals to serial outputs provided on output pins forcontrolling mechanical resources. To map I/O pins to code I/O, table2011 includes a pin number column 2019. Not all PLC signals in column2015 includes a pin number as some signals are internal to PLC 9814. Forexample, “1stclamps extend request” 2137 is a condition which isinternal to PLC 9814 and therefore, does not correspond to a pin number.

HMI 8437 is linked to controller 2001 via a two-way serial bus 2023 forretrieving PLC I/O which is to be monitored and for providing commandsignals for manual PLC control. HMI 8437 includes screen 7005 and bothan HMI configuration/linking table 2027 and a diagnostics linking table2751.

Referring to FIG. 95, exemplary HMI touch screen 7005 includes extendbutton 7019, retract button 7021 and manual button 1001. In addition,screen 7005 includes both “1st cylindicator extend signal” and “1stcylindicators retract signal” indicators 7023 and 7025, respectively.

Hereinafter, while many different control tools and indicators arecontemplated, in order to simplify this explanation it will be assumedthat the exemplary HMI only supports a single type of binary button anda single type of binary indicator.

Referring still to FIGS. 95 and 101, to define and support HMI screen7005, an HMI configuration table 2027 must include at least three typesof information. First, for each tool to be included on screen 7005, thetable must indicate tool type (e.g. indicator or button). Second, foreach tool, the table must specify a corresponding label (e.g. extend,retract, “1st cylindicator extend signal”, etc.). Third, for each tool,the table must specify a corresponding PLC signal to, in the case of anindicator, be monitored and, in the case of a control button, becontrolled.

To this end, referring also to FIG. 103, exemplary parameterized HMItable 2027 includes a tool column 2029 and an I/O column 2031. Toolcolumn 2029 includes three sub-columns including a CA instance column2701, a label column 2703 and a type column 2705. Referring also to FIG.72, instance column 2701 lists all CA instances in bar chart 5830 whichrequire HMI indicators or control buttons. 1stclamps instance 7017appears in column 2701.

Referring to FIGS. 102 and 103, signal column 2031 lists all PLC signalsfrom PLC I/O table column 2015 for each CA instance in column 2701 whichmust be either monitored or controlled. Referring also to FIG. 86,consistent with HMI specification 9460, “1stclamps I1”, “1stclamps I2”,“Manual”, “1stclamps extend request control” and “1stclamps retractrequest control”, 8046,8049,2131, 2135 and 2136, respectively, areincluded in column 2031.

Type column 2705 lists the tool type required to monitor or control PLCsignals in column 2031. To this end, indicators are listed for PLCsignals to be monitored while buttons are listed for signals to becontrolled. For example, indicator 7023 is specified for “1stclamps I1”signal 8046. Label column 2703 lists a label for each tool in column2705. Label-type pairs are singularities which correspond to indicatorsand control buttons which appear on HMI screen 7005. For example,referring also to FIG. 95, indicator 7023 and its corresponding label inFIG. 103 corresponds to indicator 7023 in FIG. 95. Indicator 7025 andits corresponding label “1st cylindicators retract signal” correspond toindicator 7025. Similarly, button 1001 and label “Manual” correspond tobutton 1001, button 7019 and its label in FIG. 103 correspond to extendbutton 7019 and button 7021 and its label in FIG. 103 correspond toretract button 7021.

Referring again to FIG. 95, diagnostic section 7007 of screen 7005provides text error messages to a system operator when a supporteddiagnostic condition occurs. To support diagnostics functions, adiagnostics table must include at least two types of information. First,for each supported diagnostic condition, the diagnostics table mustidentify a PLC signal which indicates occurrence of the diagnosticcondition. Second, for each supported diagnostic condition, the tablemust specify the message to be provided.

To this end, referring to FIGS. 101 and 104 exemplary parameterizeddiagnostics linking table 2751 includes a “link” column 2753 and anactivity column 2755. Referring also to FIG. 102, link column 2753 listsPLC signals from column 2015 which correspond to supported diagnosticconditions. In exemplary table 2751 in the interest of brevity, only twosupported conditions are listed including 1stclamps extend sensor error”8113 and “1stclamps cylinder failure” 8048.

Column 2755 includes a text phrase to be provided in diagnostics section7007 of screen 7005 when a corresponding signal in column 2753 isactive. Thus, when signals 8113 is active (as specified in table 110),the phrase 2759 to be provided in section 7007 is cylindicator sensorfailure. When signal 8048 is active, the phrase 2761 is provided.

Thus, referring to FIGS. 95 and 101 through 104, in addition toexecution code 2013, PLC I/O table 2011 is required to link code 2009 toI/O card pin numbers and hence to mechanical resources, HMIconfiguration/linking table 2027 is required to configure HMI screen 95and to link HMI buttons and indicators to PLC signals in table 2011 anddiagnostics linking table 2751 is required to link diagnostic signalsfrom PLC I/O table 2011 to diagnostic activities reported on HMI screensection 7007.

4. Compiler

Referring to FIGS. 72, 90, 95, 102, 103, and 104, compiler 9812 accessesbar chart 5830 and corresponding CA instances in database 9810 and usesinformation therein to generate control products including executioncode 2009 to be run by PLC 9814 to drive control mechanisms in themanner required by bar chart 5830, and PLC I/O table 2011 for mappingcode I/O to I/O card 2003 pins, HMI configuration/linking table 2027 todefine one or more HMIs including HMI indicators for monitoring andbuttons for manually controlling control mechanisms in a mannerconsistent with the CA instances and to link indicators and buttons toPLC signals, a diagnostics linking table 2751 for linking diagnostic PLCsignals to diagnostic activities and a schematic representation of theentire control system which is also consistent with the CA instances. Inaddition, in this embodiment, compiler 9812 also generates a simulationtable for driving virtual simulator 9816.

Compiler 9812 is linked to database 9810 via a two-way bus 8013 and isalso linked to PLC 9814, simulator 9816, HMI workstation 8437 andprinter 8436 via buses 8323, 8442, 8434 and 8444, respectively. Duringcompilation compiler 9812 also stores information on database 9810 andmay store the final control products on database 9810 as well.

Referring now to FIG. 105, compiler 9812 includes a bar chartdeconvolver 8002, a CA parser 8005, a code compiler 8007, an HMIcompiler 8009, a schematic compiler 8011 and a simulation compiler 8010.All of the components illustrated in FIG. 101 are linked via two way bus8013.

Deconvolver 8002 performs two functions. First, referring also to FIG.72, deconvolver 8002 accesses bar chart 5830 and uses chart 5830 tosequence compilation. To this end, deconvolver 8002 works sequentiallythrough bar chart 5830, one request at a time, causing compilers 8007,8009, 8011 and 8010 to simultaneously compile information for each barchart request in an orderly fashion. For example referring to bar chart5830, deconvolver 8002 begins by causing information related to the“2ndpins engage” request 5201 (i.e. the first request in chart 5830) tobe processed and compiled by each of compilers 8007, 8009, 8011 and8010. Thereafter, deconvolver 8002 causes information related to the“Gripper controller Load-Cycle” request 5203 to be processed andcompiled and so on.

While compilers 8007, 8009, 8011 and 8010 generally process informationfor a request simultaneously, in the exemplary embodiment aparameterized PLC I/O table generated by code compiler 8007 is providedto schematic compiler 8011 and therefore, some intra-request informationprocessing is sequential. Nevertheless, in the present example allcompilation for one request is completed prior to initiating compilationcorresponding to a subsequent request.

To cause compilation, deconvolver 8002 provides a “current request”signals to parser 8005 via bus 8013 indicating a single bar chartrequest at a time for which information is to be compiled. When parser8005 receives a current request signal, parser 8005 provides a sub-setof CA information for the current request to each compiler 8007, 8009,8011 and 8010. Then, compilers 8007, 8009, 8011 and 8010 processreceived information to generate control products. When each compiler8007, 8009, 8011 and 8010 has completed its processing, the compilersends a “request complete signal” to deconvolver 8002 via bus 8013. Whendeconvolver 8002 receives a request complete signal from each compiler8007, 8009, 8011 and 8010, deconvolver 8002 provides the next request inbar chart 5830 as a next current request signal to parser 8005.

After information corresponding to the last request in bar chart 5830has been processed, when deconvolver 8002 receives request completesignals from each of compilers 8007, 8009, 8011 and 8010, deconvolver8002 provides an “end sequence signal” to each of compilers 8007, 8009,8011 and 8010 indicating that the final compiling steps should beperformed and final parameterized control products should be provided.

Hereinafter, consistent with the present example, processing andcompilation is described in the context of the “1stclamps extend”request 5701 in FIG. 72.

Second, deconvolver 8002 also identifies safeties and interlocks frombar chart 5830 and generates a safeties/interlocks (S/I) table whichcorrelates CA instances with safeties and interlocks. The S/I table isprovided to compiler 8007 via bus 8013. Although not illustrated, theS/I table is described in more detail below.

Referring still to FIGS. 72 and 105, in addition to receiving thecurrent request signal, parser 8005 also accesses each CA instancecorresponding to bar chart 5830 and parses the instances into theirseparate CA specifications. Thus, referring also to FIG. 84, parser 8005separates each CA instance into a logic specification 9002, a schematicspecification 9004, an HMI specification 9006, a diagnosticspecification 9008 and a simulation specification 9300.

The specification sub-sets corresponding to each specific bar chartrequest are simultaneously provided to each compiler 8007, 8009, 8011and 8010. For example, when deconvolver 8002 indicates that the“1stclamps extend” request is to be processed, parser 8005 providesspecification sub-sets corresponding to the 1stclamps extend request toeach of compilers 8007, 8009, 8011 and 8010.

The specification sub-set provided to compiler 8007 includes logic, HMIand diagnostic specifications 9002, 9006 and 9008, respectively. Thespecification sub-set provided to HMI compiler 8009 includes the HMIspecification 9006 and diagnostic specification 9008. The sub-setprovided to compiler 8011 includes schematic specification 8003. Thesub-set provided to simulation compiler 8010 includes only thesimulation specifications 9300. Each of the compilers 8007, 8009,8011and 8010 is described separately below.

In addition to storing bar chart 5830, CA type templates andinstantiated CA instances corresponding to the stored bar chart,database 9810 also stores a plurality of database tables includinginformation which compiler 9812 combines with CA instance information togenerate the control products. The tables include a code building table(see FIG. 106), an HMI building table (see FIG. 110), a diagnosticsbuilding table (see FIG. 111) a schematic building table (see FIG. 113)and a simulation building table (see FIG. 115). Content and use of thebuilding tables is described below.

In the example which follows, while many different methods (e.g.building, duplicating, canceling, etc.) for parameterizing code, supporttables, schematics and simulation tools are contemplated, only a singlemethod which is particularly easy to visualize is described here inorder to simplify this explanation. Generally, according to the methoddescribed herein, virtually all information which might be required tosupport a control product is defined and, upon compilation some of thedefined information is eliminated. For example, with respect toexecution code, code required to support every aspect, including bothrequired and parameterizable aspects, of a CA request is provided and,upon compilation, code rungs which correspond to required and selectedrequest characteristics remain in the code while rungs corresponding toun-selected request characteristics are effectively removed from thecode. a. Code Compiler Referring to FIGS. 72, 101 and 105, compiler 8007receives logic, HMI and diagnostic specifications and the S/I table fora specific CA instance, gleans information therefrom and applies a setof rules to the gleaned information to generate parameterized executioncode segments and to form PLC I/O table sections for each bar chart 5830request. Parameterized code segments are appended to each other insequential order to form complete execution code 2009 for controllingthe control process defined by bar chart 5830 and associated CAinstances. Referring also to FIG. 102, the PLC I/O table sections arecombined to form complete PLC I/O table 2011.

The rules applied by compiler 8007 to build execution code 2009 and PLCI/O table 2011 are stored in a code building table on database 9810.Referring to FIG. 106, exemplary code building table 8021 definesvirtually all execution code which may possibly be required to supportCA instances in a control bar chart assembled using resource editor9802. Thus, table 8021 defines code corresponding to every selectable CAtype, every selectable CA request, every required CA type control deviceand characteristic, every selectable CA type device and characteristic,every selectable monitorable/controllable parameter or condition andevery selectable diagnostic requirement/activity combination.

While virtually all code which may be required is defined in table 8021,only code corresponding to required and selected (i.e. instantiated) CAtypes, characteristic, devices, HMI features and diagnostic combinationsis compiled. Thus, for example, while code corresponding to a “pinset”CA type 8012 is defined in table 8021, if, upon selecting resources forcontrol via resource editor 9802, a control engineer does not select andinstantiate at least one “pinset” CA instance, the code corresponding tothe “pin set” CA type 8012 it not compiled.

Table 8021 includes a CA type/request column 8023, a code column 8025,an I/O column 8026 and a parameterizing rule set (PRS) column 8027.Column 8023 lists every CA type which is selectable by the controlengineer via resource editor 9802. In the present example, among otherCA types, column 8023 includes the “SafeBulkHeadClampSet” type of which1stclamps is a single instance. For each CA type, column 8023independently identifies each request in the CA type logicspecification. For example, referring again to FIG. 85, each“SafeBulkHeadClampSet” CA type includes both an extend request and aretract request. Thus, in column 8023, under the “SafeBulkHeadClampSet”type 8029, each of the “extend” and “retract” requests 8033, 8035,respectively, are listed.

In addition to requests which are associated with a logic specification,a “manual” request 8038 which is associated with a corresponding HMIspecification is listed under each CA type. The manual request 8038corresponds to execution code which may be required to support manualoperation of control mechanisms associated with a CA instance. Unlikecode associated with a logic specification request (e.g. extend,retract), code associated with the manual request is generally onlyprovided once in an execution code.

Code column 8025 includes an RLL segment corresponding to each requestin column 8023. Each RLL segment includes LL rungs corresponding toevery possible control device and characteristic which may be associatedwith the corresponding request. Referring to FIG. 107, exemplary“SafeBulkHeadClampSet” extend request code segment 8032 is illustrated.Segment 8032 is abbreviated to simplify this explanation and, inreality, would include many more rungs. As illustrated, segment 8032includes a “safety” rung 2045, a “1stclamps extend request” rung 8033and a “1stclamps done” rung 8055. As illustrated, segment 8032 hasalready been partially parameterized to associate segment 8032 with the1stclamps CA instance. For example, many contacts and coils in FIG. 107include a descriptor including the term 1stclamps. It is contemplatedthat prior to compilation, the term “name” would appear in FIG. 103Aeach time 1stclamps appears. Upon compilation, the term “name” isreplaced by the CA instance name (i.e. 1stclamps). Similarly, othercontact descriptors may be parameterized upon compilation.

Safety rung 7045 renders the 1stclamps extend request dependent oncompletion of at least one and perhaps several requests or conditions inbar chart 5830. For example, in FIG. 72, the 1stclamps extend request5701 should not begin until the dumps extend request 2041 has beencompleted at edge 5529. In addition, other conditions or request donestates may have to occur prior to execution of the 1stclamps extendrequest 5701. These other conditions are reflected by the conditionscorresponding to bar chart yield icons (e.g. 5703 in FIG. 72).

Referring to FIGS. 102 and 107, contacts and coils in FIG. 107correspond to PLC I/O signals which have identical names in table 2011.For example, when the status of “1stclamps I1” 8046 turns from passiveto active in table 2011, contact “1stclamps I1” 8046 in rung 8055closes, when coil “1stclamps extend done” 2727 in rung 8055 is excited,signal “1stclamps extend done” 2727 in table 2011 changes from passiveto active and so on.

Referring still to FIGS. 72 and 107, rung 2045 makes 1stclamps extendrequest 5701 dependent upon completion of dumps extend request 2041 andupon completion of other safety conditions (not specified). A completedrequest is referred to hereinafter as a “done” request. Rung 2045includes a “dumps extend done” contact 2047 and first and second“safety” contacts 2049, 2051 in series with a “1stclamps extend request”coil 2053. As with the 1stclamps descriptors, the descriptor “dumpsextend done” reflects parameterization which is consistent with barchart 5830. Initially, a generic identifier such as “previous requestdone” is linked to contact 2047. Upon compilation, the phrase “previousrequest” would be replaced with the phrase “dumps extend”.

In the present example, rung 2045 has been configured to accommodate amaximum of two safeties and hence there are only two safety contacts2049, 2051. However, it is contemplated that a “SafeBulkHeadClampSet”instance may require more than two safeties and for that purpose, codesegment 8032 would include additional series contacts, one for eachadditional safety.

Referring still to FIGS. 72 and 107, when the dumps extend request 2041is done, contact 2047 closes. Similarly, when each of the first andsecond safety conditions corresponding to contacts 2049 and 2051 aredone, contacts 2049 and 2051, respectively, close. When all of contacts2047, 2049 and 2051 close, coil 2053 is excited. When “1stclamps extendrequest” coil 2053 is excited, related “1stclamps extend request”contacts (e.g. contact 8035 in rung 8033) close. Thus, rung 8033 isdependent on each of the conditions associated with contacts 2047, 2049and 2051 occurring.

Because rung 2045 is a safety rung, the conditions represented bycontacts 2047, 2049 and 2051 need not be maintained during execution of1stclamps extend request 5701. Thus, branches 2091 and 2093 are providedwhich, after the conditions corresponding to contacts 2047, 2049 and2051 have been met, override the safety conditions and thereby enablethe extend request despite the current status of the safety conditions.Branch 2091 includes a “1stclamps safety override” contact 2095 inseries with a “not 1stclamps retract request” contact 2101, the seriespair in parallel with contacts 2047, 2049 and 2051. Branch 2093 includesa “1stclamps safety override” coil 2097 in parallel with coil 2053. Whenthe term “not” is included in a contact label, the term “not” indicatesthe opposite of the condition modified thereby. For example, withrespect to contact 2101, “not” means that a 1stclamps retract requesthas not been made. After a 1stclamps retract request is made, contact2101 opens.

In operation, referring to FIGS. 72 and 107, after dumps extend request2041 has been completed, contact 2047 closes. Similarly, when conditionscorresponding to contacts 2049 and 2051 occur, contacts 2049 and 2051close causing each of coils 2053 and 2097 to excite. Coil 2097 causescontact 2095 to close. It is assumed that the 1stclamps retract requestis not pending and therefore contact 2101 remains closed. Thus, afterall of contacts 2047, 2049 and 2051 close, those contacts are bypassedby closed contacts 2095 and 2101 until a 1stclamps retract requestoccurs which opens contact 2101. During this bypass period, coil 2053remains excited and therefore contacts associated therewith remainclosed. When contact 2101 opens, (i.e. when a 1stclamps retract requestoccurs), coil 2097 is no longer excited and therefore contact 2095 opensand safeties 2047, 2049 and 2051 are again functional to limit the next1stclamps extend request.

Rung 8033 is designed to cause 1stclamps to extend when “1stclampsextend request” coil 2053 or some other identically named coil isexcited. Rung 8033 includes a “1stclamps extend request” contact 8035and first and second interlock contacts 2077 and 2079, respectively, inseries with a parallel coil arrangement including coils 8037, 8039, 8041and 8043 corresponding to outputs 01, 02, 05 and 06, respectively.

The interlock contacts 2077 and 2079 render a corresponding requestdependent on completion and maintenance of corresponding conditions.Thus, if an interlock condition ceases to exist during execution of adependent request, request execution is halted. Referring also to FIG.72, interlock conditions are reflected by the conditions correspondingto bar chart stop icons (e.g. 5707). Each of contacts 2077 and 2079 arelinked to a separate interlock condition. When an interlock condition isdone, the corresponding contact 2077 or 2079 is closed. When aninterlock condition is not done the corresponding contact is open.

As with safeties above, a “SafeBulkHeadClampSet” CA instance 8029 may beinterlocked to more than two conditions and in this case, additionalcontacts, one for each additional interlock contingency, would beprovided in series with contacts 2077 and 2079.

Referring to FIGS. 102 and 107, when all contacts 8035, 2077 and 2079are closed, coils 8037-8043 are excited or activated and their status ina PLC I/O table 2011 is updated. When the PLC I/O table 2011 is updated,the active output signals cause valves associated therewith via I/O pins(e.g. P1, P2, etc.) to provide air to cylindicators linked thereto toextend associated clamps.

Referring still to FIG. 107, “1stclamps extend done” rung 8055 indicateswhen a 1stclamps extend request has been completed or is done. Rung 8055includes, among other components, a “1stclamps I1” contact 8049, a“1stclamps I3” contact 8057, a “1stclamps I5” contact 8052 and a“1stclamps I7” contact 8054 in series with a “1stclamps extend done”coil 2727. Referring also to FIG. 85, contacts 8049, 8057, 8052 and 8054correspond to cylindicator extended solenoid sensor signals I1, I3, I5and I7. When each of signals I1, I3, I5 and I7 is active, contacts 8046,8057, 8052 and 8054, respectively, close and coil 2727 is excitedindicating that the 1stclamps extend request has been completed.Although not illustrated, referring also to FIG. 72, when coil 2727 isexcited, a contact corresponding to edge 5527 closes indicating that the1stclamps extend is done and that, at least with respect to thatcontingency, the “operator-station 1 Load-Part” request 2107 can begin.

Other rungs and branches which may be required to supportparameterization include diagnostic rungs and branches corresponding todiagnostic functions which are selectable via diagnostics editor 9806(see FIG. 90). Diagnostic functions are listed in the diagnostics tablein FIG. 87.

While it is contemplated that segment 8032 would include LL rungs tosupport virtually every possible diagnostic requirement/activity, in theinterest of simplifying this explanation, only two exemplary rungs areillustrated and described. For example, referring to FIG. 87, withrespect to cylindicator 9425, 1stclamps cylinder failure requirement9622 occurs when each of proximity sensor inputs I1 and I2 indicateproximity of a valve piston. Upon the occurrence of requirement 9622, adiagnostics message is required as specified by activity 8517.

In FIG. 107, branch 8077 defines code to recognize requirement 9622facilitate activity 8517 when requirement 9622 occurs. To this end,branch 8077 is in series with contact 8046 and includes “1stclamps I2”contact 8049 in series with “1stclamps cylindicator failure” coil 8048.Contacts 8046 and 8049 correspond to inputs I1 and I2, respectively, andclose when corresponding proximity sensor signals are active. When bothcontacts 8049 and 8046 close (i.e. requirement 9622), coil 8048 isexcited. Referring to FIGS. 87, 102 and 107, coil 8048 update a“1stclamps cylinder failure” signal 8048 status. Referring also to FIG.95, when coil 8048 is excited, HMI 8437 generates a diagnostic messageindicating failure as described in more detail below.

Referring still to FIGS. 87 and 107, when a 1stclamps extend requestoccurs and conditions associated with contacts 2077 and 2079 occur, ifextended proximity sensor I1 remains passive (i.e. “1stclamps I1Passive” requirement 9624), an error occurs and activity 9626 isrequired. Segment 8032 includes branch 8085 which defines code torecognize requirement 9624 and facilitate activity 9626 when requirement9624 occurs. Branch 8085 is in series with contacts 8035, 2077 and 2079,and includes contact 8111 and a series coil 8113. Contact 8111corresponds to the opposite of input I1 (i.e. if I1 is active, “not I1”is passive and vice versa). Thus, if contacts 8035, 2077 and 2079 closeto perform an extend request and contact 8111 remains closed (i.e. I1 ispassive), coil 8113 is excited. When coil 8113 is excited, HMI 8437generates the diagnostic message required by activity 9262. Although notillustrated, a delay may be provided between contact 8111 and coil 9113so that coils 8037, 8039, 8041 and 8043 and related mechanicalmechanisms have a reasonable amount of time to cause 1stclamps to extendprior to diagnostic activity 9626 occurring.

As indicated above, segment 8032 is extremely abbreviated and iscontemplated that many other LL rungs will be provided in each LLsegment. For example, additional diagnostic rungs will be provided aswell as rungs to support other parameterizable features such as latches,request restartability and so on. These additional rungs have not beendescribed here in order to simplify this explanation and because theyare not needed for an understanding of the present invention.

Referring still to FIGS. 106 and 107, although not illustrated, a codesegment 8115 corresponding to “SafeBulkHeadClampSet” CA type retractrequest 8035 is similar to code segment 8032 except that, instead ofdefining code for controlling an extend request, the retract segmentwould define code for controlling a retract request.

Referring now to FIGS. 106 and 108, an exemplary manual request codesegment 8034 is illustrated. Referring also to FIG. 86, each of1stclamps outputs 01 through 06 may be selected to be controlled duringmanual system operation. In addition, each of the extend and retractrequests may also be selected for manual control. Thus, LL rungs forcontrolling each of outputs 01-06 and extend and retract requests mustbe defined such that, if selected for compilation, the rungs can beprovided in the execution code. However, unlike requests (e.g. extend,retract, etc.) which may be performed more than once during an executioncode cycle and therefore may have to be represented more than onceduring a cycle, manual control code need only be provided once in anexecution code.

In addition, generally the location of manual code in an execution codeis unimportant. Thus, in the present example, it is assumed that, ifmanual operation is selected via HMI editor 9804 as indicated above andtherefore must be supported by execution code, the manual code is placedafter the first occurrence of any related request. For example,referring to FIGS. 72 and 106, if 1stclamps extend request 5701 is thefirst “SafeBulkHeadClampSet” request in bar chart 5830, immediatelyafter compiling code for extend request 5701, if selected via HMI editor9804, manual code is compiled and linked to the end of the extendrequest code. Thereafter, manual segment 8034 does not again appear inthe execution code.

As in the extend request code segment 8032 described above, contacts andcoils in manual segment 8034 correspond to similarly labeled andnumbered signals in table 102. Exemplary manual segment 8034 comprisesrung 8087 including a “manual” contact 2131 and a plurality of branches8063, 8065, 8091 and 8093.

If manual control is selected for compilation for 1stclamps, uponcompilation manual contact 2131 is linked to an HMI control buttonwhich, when activated, closes contact 2131. Although not illustrated, itis also contemplated that when contact 2131 is closed, the normalsequence of requests as specified by bar chart 5830 is halted untilnormal operation is again actively selected. While contact 2131 remainsclosed, branches 8063, 8065, 8091 and 8093 may be functional dependingon if related outputs or requests (i.e. 01-06, extend, retract) werepreviously selected for compilation.

Branch 8063 defines code for controlling 1stclamps 01 via HMI 8437 andincludes a contact 2133 and a coil 8103. If selected to be compiled,contact 2133 is linked to an HMI control button which, when activated,closes contact 2133. When contact 2133 closes, coil 8103 excites whichcloses a related 1stclamps 01 contact. Branch 8065 is similar to branch8063 except that a contact corresponds to a button for controllingoutput 06 and a coil corresponds to output 06. Although not illustrated,branches like branch 8063 are also provided for each of outputs 02-05.

Branch 8091 defines code for manually controlling the 1stclamp extendrequest. Branch 8091 includes a contact 2135 and a coil 8107. Ifselected to be compiled, contact 2135 is linked to an HMI control buttonwhich, when activated, closes contact 2135. When contact 2135 is closed,coil 8107 excites and closes related “1stclamps extend request”contacts. Referring also to FIG. 107, when “1stclamps extend request”coil 8107 excites, contact 8035 closes, causing outputs 01, 02, 05 and06 to excite (assuming conditions associated with contacts 2077 and 2079are met) which in turn cause control mechanisms linked thereto to extendclamps associated with the 1stclamps CA instance. Rung 8093 is similarto rung 8091 except that, instead of defining code for manual control ofthe extend request, rung 8093 defines code for manual control of theretract request.

Many of the characteristics and, indeed, for each CA type, even some ofthe control devices, are optional and therefore may or may not beselected for subsequent compilation. Therefore, referring again to FIGS.106, 107 and 108 while each code segment (e.g. 8032, 8034) defines LLrungs to support virtually every required and parameterizable CAcharacteristic for a request, every LL rung or branch in a code segmentwhich corresponds to a parameterizable (i.e. selectable orde-selectable) CA feature is provided in series or in parallel with aswitch so that the rung or branch can be discarded upon compilation.When a series switch is closed or a parallel switch is open, thecorresponding rung is compiled and when a series switch is open or aparallel switch is closed, the corresponding rung is discarded uponcompiling. In FIGS. 107 and 108 switches are identified by triangles andare labeled with descriptors “Sn” where n is an integer (e.g. S1, S2,etc.) Rungs which are required within a CA type do not include switches.For example, referring to FIGS. 85 and 107, two position valve 9421 isrequired in the “SafeBulkHeadClampSet” CA type. Therefore, no switchesare in series or in parallel with coils 8037 and 8039 (corresponding tothe required two position valve 9421). Similarly, it is required thatthe “previous request done” requirement be met prior to executing the1stclamps extend request and therefore, no switches are in series or inparallel with “dumps extend done” contact 2047.

However, spring return value 9423 is optional (i.e. in the presentexample may be selected or de-selected using resource editor 9802).Thus, switches are provided within code segment 8032 which, when open,effectively de-select code corresponding to spring return value 9423and, when closed, select code for valve 9423. In FIG. 107, switches S3and S4 correspond to valve 9423. Thus, if switches S3 and S4 are open,upon compilation branches including coils 8041 and 8043 are eliminatedfrom segment 8032.

Similarly, referring to FIGS. 87 and 107, each of diagnostics branches8085 and 8077 is optional and therefore, switches S5 and S6 are providedin those rungs, respectively. When one of switches S5 or S6 is opened, acorresponding branch is eliminated upon compilation.

Moreover, it is contemplated that the 1stclamps extend request may notbe contingent upon additional safeties and interlocks. In this case,safety contacts 2049 and 2051 and interlock contacts 2077 and 2079should be eliminated. To this end, switches S1, S2, S7 and S8 areprovided in parallel with contacts 2049, 2051, 2077 and 2079,respectively. When one of switches S1, S2, S7 or S8 is closed, aparallel contact is eliminated upon subsequent compilation.

Furthermore, referring to FIGS. 85 and 107, 2nd, 3rd and 4thcylindicators 9427, 9429 and 9431 are optional. In rung 8055, if secondcylindicator 9427 is not included in 1stclamps, contact 8057corresponding to the second cylindicator extended proximity sensorsignal I3 must be eliminated in segment 8032. Similarly, if cylindicator9429 is not included, contact 8052 must be eliminated, and ifcylindicator 9431 is not included, contact 8054 must be eliminated. Tothis end, switches S9, S10 and S11 are in parallel with contacts 8057,8052 and 8054, respectively. If switch S9, S10 or S11 is closed acorresponding parallel contact is removed from segment 8032 uponcompilation.

Referring to FIGS. 86 and 108, controllability of outputs 01-06 andcontrollability of extend and retract requests is also optional.Therefore, switches S12, S13, S14 and S15 are provided in series withbranches 8063, 8065, 8091 and 8093, respectively. When one of switchesS12-S15 is open the corresponding branch is eliminated upon compilation.

Referring once again to FIG. 106, column 8026 includes a single genericPLC I/O table segment for each CA type independent of the number ofrequests which correspond to the CA type. Generic segment 8060corresponds to “SafeBulkHeadClampSet” type 8029.

Segment 8060 includes a PLC signal list corresponding to anunparameterized “SafeBulkHeadClampSet” CA type. In other words, the PLCsignal list in table 8060 includes signals which must be included in aPLC I/O table when a “SafeBulkHeadClampSet” CA type instance isinstantiated, regardless of parameterization. For example, referringalso to FIG. 107, for CA type 8029, generic segment 8060 includes everycontact in segment 8032 which is not in series or in parallel with aswitch S1-S11. In addition, referring to FIG. 108, table 8060 includesevery contact in segment 8034 which is not in series or in parallel withone of switches S12-S15. In segment 8034 all contacts are in series orparallel with at least one of switches S12-S15 and therefore, unlessalso included in one of segments 8032 or 8035 none of those contacts isincluded in the initial PLC signal list.

Generic segment 8060 is modified by compiler 8007 as a function ofparameterization. Eventually, in the present example and aftercompilation, generic segment table 8060 looks like table 2011 includingsignals in column 2015 corresponding to every contact and coil inparameterized and compiled code segments 8032, 8115 and 8034 (i.e.corresponding to all “SafeBulkHeadClampSet” requests).

Referring still to FIG. 106, PRS column 8027 includes a separate PRStable corresponding to each request in column 8023. An exemplary PRStable 8201 which corresponds to the “SafeBulkHeadClampSet” CA typeextend request 8033 is illustrated. PRS table 8201 includes aparameterization column 8203, a code modification column 8205 and a PLCI/O table modification column 8207.

Column 8203 includes a list of possible parameterizations correspondingto the CA type and request in column 8023. Each parameterization incolumn 8203 is associated with a separate one of the flag boxes in oneof specifications 9002, (see FIG. 85), 9006 (see FIG. 86) or 9008 (seeFIG. 87) or is associated with a yield or stop icon in FIG. 72. Forexample, referring also to FIG. 85, one parameterization 8209 includes“flagged box 9480 a” indicating selection of spring return valve 9423.Referring to FIGS. 87 and 106, second exemplary parameterization 2731 is“flagged box 9490” indicating selection of the 1stclamps extend requestto be controlled via an HMI. Many other parameterizations arecontemplated and would be listed in column 8203.

Column 8205 includes modifications to the code segments in column 8025which correspond to specific parameterizations in column 8203. Forexample, modification 8217 corresponding to the “flagged box 9480 a”parameterization 8209 is to close switches S3 and S4. Referring also toFIG. 107, when switches S3 and S4 are closed, coils 8041 and 8043corresponding to outputs 05 and 06 are included in code segment 8032.Modification 8215 corresponding to “flagged box 9490” parameterization2731 is to close switch S14. Referring to FIG. 108, when switch S14 isclosed, rung 8091 is included in segment 8034 and manual control of the1stclamps extend request is supported by segment 8034.

Referring still to FIG. 106, column 8207 lists PLC I/O tablemodifications corresponding to parameterizations in column 8203. Forexample, referring also to FIG. 85, where box 9840 a is flagged (i.e.parameterization 8209), outputs 05 and 06 are added to segment 8060according to modification 8221. Similarly, where box 9490 is flagged(i.e. parameterization 2731), signal “1stclamps extend request control”corresponding to contact 2135 (see FIG. 108) is provided in segment 8060to facilitate manual control of the 1stclamps extend request via an HMI,and so on.

Although not illustrated in detail, PRS tables 8301 and 8303 which aresimilar to table 8201 are provided for each of retract request 8035 andmanual request 8038 and are provided for each request associated withother CA types in column 8023.

Referring now to FIGS. 7285, 86, 87 and 105, in the present example,after compiler 8007 compiles and links execution code segments for eachrequest prior to 1stclamps extend request 5701, deconvolver 8002 causesparser 8005 to provide logic, HMI and diagnostic specifications 9002,9006 and 9008, respectively, which correspond to 1stclamps extendrequest 5701 to compiler 8007 and deconvolver 8002 provides the S/Itable which corresponds to the “1stclamps extend” request to compiler8007.

The S/I table (not illustrated) is simply a table which lists all1stclamps extend request contingencies including the previous requestfrom bar chart 5830 (see FIG. 72), and all safeties and interlockslisted in yield and stop icons, respectively, which are linked to thefront edge of the 1stclamps extend request. Thus, referring to FIG. 72,the S/I table for 1stclamps extend request 5701 includes “dumps extend”request 2041 and any contingencies from icon 5703.

Referring also to FIG. 109, an exemplary compiling process performed bycompiler 8007 is illustrated. At block 8305, compiler 8007 eitherreceives an end sequence signal or an S/I table from deconvolver 8002.The end sequence signal indicates that information corresponding to thelast request in bar chart 5830 has been compiled and that finalcompilation steps should be performed by compiler 8007. At decisionblock 8315, compiler 8007 determines if an end sequence signal has beenreceived. If an end sequence signal has been received control passes toprocess block 8317. In the present example, 1stclamps extend request5701 is not the last request in chart 5830 and therefore control passesto block 8306. At block 8306 compiler 8007 receives specifications 9002,9006 and 9008 and the S/I table corresponding to the 1stclamps instance.At block 8307 compiler 8007 accesses code table (see FIG. 106) 8021 viabus 8013, identifies the “SafeBulkHeadClampSet” CA type 8029 and theextend request 8033 corresponding to 1stclamps extend request 5701 andretrieves code segment 8032, generic segment 8060 and PRS 8201.Continuing, at block 8309 compiler 8007 gleans parameterizationinformation from logic specification 9002, HMI specification 9006,diagnostic specification 9008 and the S/I table. At process block 8311compiler 8007 applies the rules from PRS table 8201 to the gleanedinformation to modify the code segment 8032 by opening/closing rungswitches and to modify PLC I/O table segment 8060 as described above. Inaddition, at block 8311 compiler 8007 substitutes the CA name (e.g.1stclamps) for generic contact and coil descriptions (e.g. “name”) incode segment 8032 and in segment 8060.

Next, at process block 8313, compiler 8007 links the parameterizedexecution code segment 8032 to previously compiled segments to continueto form a complete LL program and adds the parameterized segment 8060 toother I/O specifications corresponding to previously compiled segments.

Referring again to FIGS. 72 and 101, at this point a complete executioncode 2009 for controlling mechanical resources as required by bar chart5830 has been provided. In addition, referring to FIG. 102, columns 2015and 2017 of PLC I/O table 2011 have been defined. Next, I/O card pinshave to be assigned to I/O signals in column 2015.

Herein it is assumed PLC card 2003 includes a sufficient number of I/Oterminals to control and monitor the control system corresponding to barchart 5830 as parameterized by the CA instances related thereto. Atblock 8317 compiler 8007 assigns signals from PLC I/O table 2011 column2015 to I/O card terminals P-1, P-2 . . . P-N to fill in column 2019 andcomplete table 2011. At block 8321, compiler 8007 provides the executioncode and PLC I/O table 2011.

Referring again to FIG. 90, the execution code 2009 and PLC I/O table2011 are provided to database 9810 for storage and subsequent access. Inaddition, the execution code 2009 and I/O table 2011 are provided to PLC9814. Referring to FIG. 101, I/O table 2011 is also provided toschematic compiler 8011 via bus 8013.

At this point all of the execution code for controlling the process andcontrol mechanisms associated with bar chart 5830, the code forsupporting HMIs as required by HMI specifications and the code forsupporting diagnostics as required by diagnostic specifications has beenprovided.

It should be appreciated that while the compilation example above isdescribed in the context of a system of CAS which does not supportstatus based diagnostics, a similar process would be performed where CASinclude status based diagnostics specifications, the only differencebeing that the generated code would include additional status baseddiagnostics code. The additional code would facilitate next eventreporting such that, when a next event fails to occur, a PLC running thecode would indicate the next event to occur thereby indicating symptomsto a system user which the user could then use to determine the likelycause of failure. In this regard, the diagnostics code, a diagnosticsprocessor and a driver which indicates the next event to occur operatetogether as a diagnostics agent to report failure non-occurring events.This aspect of the invention is described in more detail below.

b. HMI Compiler

Referring again to FIGS. 84 and 101, HMI compiler 8009 receives HMIspecification 9006 and diagnostic specification 9008 from code compiler8007. Exemplary HMI specification table 9460 is illustrated in FIG. 86while exemplary diagnostic specification table 9600 is illustrated inFIG. 87. With respect to HMI table 9460, compiler 8009 gleansinformation from table 9460 and, referring also to FIG. 110, appliesrules from an HMI building table 8401 to the gleaned information toconstruct an HMI screen including indicators and control buttons and tolink the indicators and buttons to PLC signals.

To this end, building table 8401 defines virtually all HMI indicator andcontrol buttons which may possibly be required to support monitoring andcontrol of CA characteristic. Table 8401 includes a CA type column 8403,a monitorable column 8405 and controllable column 8407. Monitorablecolumn 8405 defines HMI indicators and PLC signal links whereascontrollable column 8407 defines control buttons and associated PLCsignal links. CA type column 8403 includes a list of every possible CAtype which may be selected by a control engineer using resource editor9802. For the purposes of this explanation, “SafeBulkHeadClampSet” CAtype 8029 is listed in column 8403.

Monitorable column 8405 is divided into subcolumns including an I/Ocolumn 8411, a “label” column 8413 and a “link” column. I/O column 8411includes a list of all monitorable inputs and outputs corresponding toeach specific CA type in column 8403. Thus, referring to FIGS. 86 on110, because an exemplary “SafeBulkHeadClampSet” CA type 8029 mayinclude monitorable outputs 01-06 and monitorable inputs I-1-I8, each ofoutputs 01-06 and each of inputs I-1-I8 are included in column 8411corresponding to the “SafeBulkHeadClampSet” CA type 8029. In order tosimplify FIG. 110, only an abbreviated list (i.e., 01, 02, 03 . . . I1,I2 . . . ) is provided in column 8411.

Column 8413 includes a separate label corresponding to each I/O incolumn 8411. Each label in column 8413 defines a descriptor for an HMIindicator. For example, for 01 in column 8411, the label in column 8413is “2-position value hot extend output” 8727 which describes the hotoutput 01 of two-position valve 9421 in FIG. 85. For 02, in column 8411,the label in column 8413 is “2-position value common extend out” 8729which describes the common output 02 of two-position valve 9421 in FIG.85. For 11 in column 8411 the label is “1st cylindicator extend signal”8731 which describes first cylindicator 9425 input II in FIG. 85 and for12 in column 8411 the label is “1st cylindicator retract signal” 8733which describes first cylindicator 9425 input I2 in FIG. 85.

Column 8725 includes a PLC signal link for each I/O in column 8411. Eachlink in column 8725 includes a generic descriptor “name” which, uponcompilation, is replaced with the CA instance name. Thus, in the presentexample, general descriptors “name” in FIG. 110 is replaced with1stclamps upon compilation. Link “name” I1 corresponds to I1 in column8411, link “name” I2 corresponds to I2 and so on. After compilation,link “name” I1 and link “name” I2 are replaced by “1stclamps I1” and“1stclamps I2,” respectively, which link associated indicators withsimilarly identified PLC signals 8046 and 8049, respectively, in table2011 (see FIG. 102).

Referring still to FIG. 110, controllable column 8407 is also dividedinto subcolumns including an I/O column 8417, a “label” column 8419 anda “link” column 8735. Column 8417 includes a list of all I/O andrequests which may be selected to be controllable via HMI editor 9804and which are associated with a corresponding CA type. Referring also toFIG. 86, for the “SafeBulkHeadClampSet” CA type 8029, outputs which maypossibly be selected for control include outputs 01 through 06 andrequests which may possibly be selected for control include extend andretract requests. To simplify FIG. 110, only outputs 01 and 02 arelisted.

Column 8419 includes a separate label corresponding to each I/O orrequest in column 8417. Each label in column 8419 defines a descriptorfor an HMI button. For example, for “extend” in column 8417 the label incolumn 8419 is “extend” and for “retract” in column 8417 the label incolumn 8419 is “retract.”

Column 8735 includes a PLC signal link for each I/O or request in column8417. Once again, upon compilation the generic descriptors “name” arereplaced with CA instance name “1stclamps.” Thus, after compilation,requests extend and retract are linked to “1stclamps extend requestcontrol” 2135 and “1stclamps retract request control” 2136 signals,respectively, in table 2011 (see FIG. 102).

Upon compilation, referring to FIGS. 86 and 110, compiler 8009identifies all selected I/O and requests for monitoring and control intable 9460, identifies the selected I/O and requests in columns 8411 and8417 and uses information in table 8401 to build an HMIconfiguration/linking table like table 2027 illustrated in FIG. 103. Thecompilation process is described in more detail below.

Referring to FIGS. 87 and 105, with respect to diagnostics table 9600,compiler 8009 gleans information from diagnostic specification table9600 and, referring also to FIG. 113, applies diagnostics building table8739 to the gleaned information to construct a parameterized diagnosticslinking table (see FIG. 104).

To this end, diagnostics building table 8734 includes a “requirement”column 8741, a “text” column 8743 and a “link” column 8745. Referring toFIGS. 87 and 111, column 8741 includes an entry corresponding to eachrequirement in column 9604 and text column 8743 includes an entrycorresponding to each activity in column 9606. In particular, amongother requirements and activities, “1stclamps cylinder failure”requirement 9622 and “1stclamps extend sensor error” requirement 9624and associated text activities are listed in columns 8741 and 8743.

Upon compilation, referring to FIGS. 87 and 111, compiler 8009identifies all selected diagnostics requirements for supporting in table9600 identifies the selected requirements in column 8741 and usesinformation in table 8739 to build diagnostics linking table like table2751 illustrated in FIG. 104.

Referring to FIG. 112, an exemplary compiling process performed bycompiler 8009 is illustrated. Referring also to FIGS. 101 and 105, atdecision block 8424, processor 8009 determines if deconvolver 8002 hasprovided an end sequence signal indicating the end of bar chart 5830. IFan end sequence signal has been provided, control skips to block 8435where compiler 8009 provides both HMI linking table 2027 (see FIG. 103)and diagnostics linking table 2751 (see FIG. 104). In the presentexample, 1stclamps extend request 5701 is not the last request in chart5830 and therefore control passes to block 8425.

At block 8425, referring also to FIGS. 86 and 87, compiler 8009 receivesHMI and diagnostic specifications 9006, 9008, respectively,corresponding to the 1stclamp CA instance. At process block 8427,compiler 8009 gleans HMI requirements from HMI specification 9006 andgleans diagnostic requirements from the diagnostic specification 9008.To this end, compiler 8009 identifies clear and flagged boxes in each ofcolumns 9464 and 9466, identifies CA instance name 1stclamps andidentifies clear and flagged boxes in column 9604.

Referring to FIGS. 105,110 and 112, at block 8429 compiler 8009 appliestable 8401 to the gleaned information and builds parameterized HMIlinking table 2027 as illustrated in FIG. 103. To this end, for everyselected monitorable I/O (i.e., I/O in FIG. 86 which has been flagged),compiler 8009 identifies the selected I/O in column 8411 of table 8401and copies the label and link information corresponding thereto intoparameterized HMI linking table 2027. Similarly, for every selected I/Oand request to be controlled, compiler 8009 identifies the selected I/Oor request in column 8417 of table 8401 and copies label and linkinformation into parameterized HMI linking table 2027.

Similarly, referring to FIGS. 105 and 112 at block 8429, compiler 8009applies table 8739 to the gleaned information and builds parameterizeddiagnostics linking table 2751 as illustrated in FIG. 104. To this end,for every selected requirement in table 9600 (see FIG. 87), compiler8009 identifies the requirement in column 8741 of table 8739 and copiesthe text and link information corresponding thereto into parameterizeddiagnostics table 2751.

At block 8433, compiler 8009 substitutes CA instance name 1stclamps forgeneric descriptor “name” and may substitute other specific descriptorsas required. Therefore, control passes back to block 8424.

After specifications corresponding to the last request in chart 5830have been compiled, control passes to process block 8435 whereparameterized HMI and diagnostics linking tables 2027 and 2751,respectively, are provided.

Referring also to FIG. 90, HMI and diagnostics linking tables 2027 and2751 are provided to HMI workstation 8437 via a bus 8439. It is assumedHMI 8437 includes software which, with a simple specification such astables 2027 and 2751, can configure a screen like exemplary screen 7005illustrated in FIG. 95. Station 8437 is linked to PLC 9814 via a two-waybus 8441 for controlling PLC 9414 during manual PLC operation and formonitoring PLC 9814 during both normal PLC operation and manualoperation.

At this point a complete HMI configuration for both manual and automaticcontrol and monitoring of the control process associated with bar chart5830 and corresponding CA instances have been provided. In addition,tables for linking HMI tools and diagnostic activities to PLC signalshave been provided.

c. Schematic Compiler

Referring again to FIGS. 72, 84, 85A and 105, as compilers 8007 and 8009process specifications for the 1stclamps CA extend request 5701,schematic compiler 8011 simultaneously processes 1stclamps schematicspecification 9004. Compiler 8011 gleans information from schematicsspecification 9004 and, referring also to FIG. 113, applies rule from aschematic building table 8501 to the gleaned information to build aparameterized control system schematic.

Exemplary schematic building table 8501 includes a CA type column 8503,a default schematic column 8505, and a parameterizing rule set (PRS)column 8507. Column 8503 includes a list of each CA type which a controlengineer may select using resource editor 9802. For the purposes of thepresent explanation, a “SafeBulkHeadClampSet” CA type 8029 is includedin column 8503.

Default schematic column 8505 includes a separate default schematiccorresponding to each CA type in column 8503. With respect to the“SafeBulkHeadClampSet” CA type 8029, the default schematic isillustrated in block form as 8511. As explained above, for the“SafeBulkHeadClampSet” CA type 8029, required control devices include atwo-position valve and at least a first cylindicator. Therefore, defaultschematic 8511 includes a schematic illustration showing a two-positionvalve and a single cylindicator linked together in an operative manner.

PRS column includes a separate table corresponding to each CA type incolumn 8503. Table 8513 corresponds to the “SafeBulkHeadClampSet” CAtype 8029 and includes a parameterization column 8515 and a schematicmodification column 8517.

Referring to FIGS. 85A and 113, column 8515 includes a list of possibleparameterizations which correspond to schematic specification 9004.Column 8517 includes one or more schematic modifications correspondingto each parameterization in column 8515. For example, the schematicmodification corresponding to a “flagged box 9480 f” parameterization isthat a spring return valve representation should be added to defaultschematic 8511 and linked accordingly. Thus in FIG. 85A, when springreturn valve 9523 is selected by placement of a flag in box 9480 f, thecorresponding spring return valve schematic is added to schematic 8511upon compilation.

Similarly, the modification corresponding to a “flagged box 9482 f”parameterization is that a second cylindicator schematic should be addedto the default schematic 8511 and linked accordingly. Although notillustrated, other parameterizations and associated schematicmodifications are contemplated. Default schematics and associated PRSsare provided in table 8501 for each CA type listed in column 8503.

Referring to FIG. 90, schematic I/O which are to be linked to PLC 9814are labeled with PLC signal names. For example, referring to FIGS. 85and 113, two-position valve 9421 receives four PLC outputs 01-04 andtherefore schematic 8511 illustrates four PLC outputs 01-04 for linkingto PLC 9814. The schematic outputs 01-04 are labeled “1stclamps 01”,“1stclamps 02”, “1stclamps 03”, and “1stclamps 04”. If selected forcompilation, spring return valve 9423 includes outputs “1stclamps 05”,and “1stclamps 06”, and corresponding schematic outputs for valve 9423are so labeled. Cylindicator inputs I1 through I8, if selected aresimilarly labeled on the schematic.

After a parameterized schematic diagram for the 1stclamps CA instancehas been provided, the diagram is linked to previously parameterizeddiagrams corresponding to other CA instances associated with bar chart5830. Once all parameterized schematics have been linked and aftercompiler 8007 has generated a complete PLC I/O table 2011 (see FIG.102), table 2011 is provided to schematic compiler 8011. Compiler 8011then schematically links I/O card pin numbers to similarly namedschematic I/O. For example, “1stclamps 01” is schematically linked tothe pin number corresponding to “1stclamps 01” in table 2011, “1stclampsI1” in the schematic is schematically linked to the pin numbercorresponding to “1stclamps I1” in table 2011 and so on.

Referring now to FIG. 114, an exemplary compiling process performed bycompiler 8011 is illustrated. At decision block 8533 compiler 8011determines if an end sequence signal indicating the end of bar chart5830 has been received from deconvolver 8002. Where an end sequencesignal has been received control passes to block 8535. Where an endsequence signal has not been received control passes to block 8525.

Referring also to FIG. 85A, at block 8525 compiler 8011 receives1stclamp schematic specification 9004. At process block 8527 compiler8011 gleans information from schematic specification 9004. Referringalso to FIG. 113, at block 8529 compiler 8011 accesses schematicbuilding table 8501, identifies the CA type as a “SafeBulkHeadClampSet”type and identifies the default schematic 8511 and PRS table 8513.

Continuing, at process block 8531, compiler 8011 parameterizes defaultschematic 8511 as a function of gleaned information and in the mannerspecified by PRS table 8513 and links the parameterized schematic topreviously parameterized schematics. Thereafter control passes back upto decision block 8533.

After the end sequence signal is received and control passes to block8535, referring also to FIGS. 102 and 105, compiler 8011 receives PLCI/O table 2011 from code compiler 8007 and schematically links schematicI/O to pin numbers in column 2019 which correspond to signals in column2015 which have names in common with the schematic I/O. Thereafter, atblock 8536, compiler 8011 provides the complete parameterized controlsystem schematic.

Referring again to FIG. 90, the schematic can be stored on database 9810and/or can be printed out via printer 8436.

d. Simulation Compiler

Referring to FIG. 88 and 105, as compilers 8007, 8009 and 8011 compilespecifications corresponding to CA instance 1stclamps, simulationcompiler 8010 simultaneously receives simulation specification 9300corresponding to the 1stclamps CA instance. Referring also to FIG. 115,compiler 8010 gleans information from simulation specification 9300 (seeFIG. 88) and applies rules from simulation building table 2901 to thegleaned information to generate video and feedback tables which are inturn used to drive simulator 9816 (see FIG. 90).

To this end, table 2901 includes a CA type column 2899, a“parameterization” column 2903 and a “modifications” column 2405. CAtype column 2894 lists every CA type which may be selected via resourceeditor 9802. For the purposes of the present invention“SafeBulkHeadClampSet” CA type 8029 is included in column 2894.

Referring to FIGS. 88 and 115, parameterization column 2903 lists everypossible parameterization which may be selected via resource editor 9802which may alter and eliminate any aspect of a video or feedback tablecorresponding to the related CA type in column 2894. For CA type 8029,in the interest of brevity, only two parameterizations are listed incolumn 2903 including “clear box 9482 d” parameterization 2907 and“clear box 9480 e” parameterization 2904. Many other parameterizationsare contemplated. Column 2905 includes one or more modifications tospecification 9300 corresponding to each parameterization in column2903. For example, modification 2911 is to “delete table 9303” when box9482 d is clear. Referring also to FIG. 85, box 9482 d corresponds tobox 9482 a and hence is clear only when box 9482 a is clear indicatingthat a particular CA instance does not require the second cylindicator(i.e. second cylindicator 9427 was not selected). Where secondcylindicator 9427 is not selected, video table 9303 is not needed andtherefore is deleted.

As another example, modification 2913 is to “delete combination 9320”when box 9480 e is clear. Referring also to FIG. 85, box 9480 ecorresponds to box 9480 a and hence is clear only when box 9480 a isclear indicating that a particular CA instance does not require thespring return valve 9423 (i.e. value 9423 was not selected). Where value9423 is not selected, combination 9320 no longer is accurate andtherefore is deleted.

Referring now to FIG. 116, an exemplary compilation process performed bycompiler 9810 is illustrated. At decision block 2915 compiler 8010determines if an end sequence signal has been received from deconvolver8002. If an end sequence signal has been received, control passes toblock 2917 where compiler 8010 provides all of the parameterized videoand feedback tables. If an end sequence signal has not been received,control passes to block 2919.

At block 2919, compiler 8010 receives the simulation specificationcorresponding to the next request in chart 5830 to be compiled. In thepresent example, compiler 8010 receives simulation specification 9300(see FIG. 88) corresponding to CA instance 1stclamps. Continuing, atblock 2921 compiler 8010 gleans parameterization information fromspecification 9300. At block 2923, compiler 8010 accesses simulationbuilding table 2901 and identifies CA type “SafeBulkHeadClampSet” 8029and corresponding parameterizations and modifications. At block 2925compiler 8010 parameterizes tables in specification 9300 according tothe modifications in table 2901 and then control passes back up todecision block 2915.

Referring to FIGS. 88, 90 and 116, after the end sequence signal isreceived at block 2915 and control passes to block 2917, compiler 8010provides a complete set of simulation tables to simulator 9816 via bus8442.

At this point virtually all controls products have been generated forconstructing, simulating and controlling the control system and controlprocess specified in the control bar chart 5830 of FIG. 72. Referringalso to FIG. 101, the control products include an execution code 2009, aPLC I/O table 2011, HMI configuration/linking table 2027, diagnosticslinking table 2751, a schematic diagram and a simulation table.

An engineer can use the control tools to simulate operation of themechanical resources or to configure actual mechanical resources therebybuilding a machine line. In either case, after configuring a line(either virtually or in the real world), a PLC or a soft PLC (i.e., aPLC model run using software) can be used to control the mechanicalresources and to generate diagnostic messages which indicate next eventsto occur. When an expected event does not occur, the diagnostic messageindicates the event which did not occur to help an operator determinethe cause of the failure.

5. Core Modeling System

Referring to FIGS. 72, 88, 90 and 101, after the execution code 2009 andI/O table 2011 have been provided to PLC 9814, each of HMI linking table2027 and diagnostics linking table 2751 have been provided to HMI 8437and a parameterized set of simulation tables (i.e. video and feedbacktables) have been provided to CMS 9816, HMI 8427, PLC 9814, CMS 9816,module 9818 and screen 9820 can be used to virtually simulate theprocess specified by bar chart 5830 and corresponding CA instances. Tothis end, PLC 9814 is linked to CMS 9816 via a two way bus 6901, CMS9816 is linked to module 9818 via a two way bus 6903 and module 9181 islinked to screen 9820 via a bus 6905.

To simulate the process of bar chart 5830, PLC 9814 runs the executioncode stored therein under the direction of HMI workstation 8437. PLCoutputs are provided to CMS 9816 via bus 6901. Referring also to FIG.88, CMS 9816 accesses parameterized video tables and based on outputcombinations, selects one or more video clips to be played via screen9820 to virtually present the process of chart 5830. Video clip commandsare provided by CMS 9816 via bus 6903 to module 9818. Module 9818accesses the video clips required by the received video clip requestsignals and plays the clips on screen 9820.

As described above, in this embodiment module 9818 is capable ofidentifying specific events during the playing of video clips andproviding feedback signal indicating the event. For example, module 9818can recognize the end of a video clip and send one or more feedbacksignals to CMS 9816. When a feedback signal is received, CMS 9816accesses a feedback table and identifies PLC input signals whichcorrespond to the feedback event. For example, when a 1stclamps extendvideo is completed, 1stclamps I1 and 1stclamps I2 PLC inputs should bechanged to “1” and “0”, respectively, (see 9304 in FIG. 88).

CMS 9816 provides the feedback PLC input signals to PLC 9814 via bus6901. When the input signals are received, referring also to FIG. 101,controller 2001 modifies I/O table 2011 accordingly which affectsoperation of code 2009.

Referring still to FIGS. 72, 88 and 90, in the alternative, it iscontemplated that CMS 9816 may be capable of animating actual CAD imagesof mechanical resources in the manner prescribed by bar chart 5830.

Although a relatively simple simulation system is described abovewherein compilation of a simulation specification results in a PLCmapping table for effectively converting PLC I/O into video commands formodule 9818, other simulation systems are contemplated which supportother than a one-to-one conversion of I/O combinations to video clips.In this regard, it has been recognized that most mechanical resources donot respond in an ideal manner to requests to perform activities andthat operation of mechanical resources in response to specific I/Ocombinations are not always identical for various reasons. As a simpleexample, consider a hydraulic clamp and an I/O combination whichindicates that the clamp should be extended. Ideally, upon receiving anextend request the clamp immediately changes its position from retractedto extended. In reality, however, because the clamp has mechanicalcomponents, clamp extension is not instantaneous but rather requires afinite time. Thus, the mechanical nature of the clamp renders idealoperation impossible (i.e., instantaneous extension is impossible).

An approximation of actual clamp operation can be facilitated byassuming a clamp requires an exemplary estimated amount of time toextend. For example, it may be assumed clamp extension requires fiveseconds. In this case a simulated video clip may be controlled such thata clamp extension appears to require five seconds to close. While a fivesecond rule may more closely reflect reality than instantaneous closure,such a rule is, as indicated above, nothing more than another estimateof reality which may or may not be accurate.

In most cases a single rule such as extension time will be inaccurate tosome unspecified degree. Variance between operation in reality and anestimated operating rule can be attributed to a plethora of sources. Forexample, in most cases the mechanical resources associated with a CA maybe configured using hardware manufactured by any of several differentvendors. In the case of clamp extension, all other things being equal,clamp hardware from one vendor may extend in three seconds while anothervendor's clamp hardware may require six and one-half seconds while stillanother vendor's hardware may extend in five seconds. Clearly, in thiscase, an estimate of five seconds for clamp extension would beinaccurate much of the time.

As another example, variance may also be attributed to resourceenvironment. For instance, a clamp which extends in five seconds in a70° F. plant where the humidity level is 20% may require nine secondswhen the temperature is reduced to 0° F. and 0% humidity and may requireseven seconds where the temperature is 70° F. and the humidity is 60%.

Still another exemplary variance source is temporally proximateoperation. For instance, a clamp which is routinely and rapidly extendedand retracted may require a shorter extension period than the same clampif the clamp is infrequently extended and retracted. Other variancesources (e.g., wear and tear) are contemplated.

While operating approximations may be sufficient in some simulationapplications, such approximations are often insufficient. This isparticularly true in complex simulation applications where two or moremechanical resources may cause components to travel within the samespace at different times. Similarly, operating approximations areinsufficient where process time is important for cost justificationpurposes. In these cases it is extremely important that, to the extentpossible, operating characteristics of resources be modeled as preciselyas possible.

Furthermore, discrete event simulation which simply simulates eventorder and which does not reflect event duration is relatively uselessfor simulating fault or exception (i.e., process description)management. For instance, with a discrete event simulator, if a usersimulates a faulty clamp extend sensor by disabling the sensor, thediscrete event simulator simply simulates subsequent events in rapidsuccession until a “wait” state is achieved. In this case, because thesubsequent events are rapidly simulated, very little can be gleaned fromthe simulation about how the PLC actually managed the faulty condition.

It has been recognized that “relative time” simulation is a betteralternative to discrete event simulation for the purpose of identifyingfault management operation and capabilities. To this end, it iscontemplated that a simulator includes a relative time clock (notillustrated) which, during simulation, maintains relative time periodsof event execution. For example, if extension of one clamp type requirestwo minutes and extension of a second clamp type requires one minute,while the simulator may be programmed to compress event execution time,the period duration ratio remains the same such that, if simulation ofthe first clamp type is compressed to twenty seconds instead of twominutes, simulation of the second clamp type is compressed to tenseconds to maintain the 2-to-1 ratio. Thus, mechanical resourceoperating variances corresponding to both event execution and faultmaintenance must be specified for each mechanical resource.

Unfortunately it would be extremely difficult to specify all resourceoperating characteristics (e.g., stroke speed, temperature and humidityeffects, etc.) within a CA. While this task is possible and iscontemplated by another embodiment of this invention, a huge number ofparameterizations and contingencies would have to be specified withinthe CA which would render the above described parameterization processdaunting. For example, resource hardware, operating environment, recenttemporal activities and so on would have to be specified for eachresource during parameterization. In addition, to modify any one ofthese aspects a new CA would have to be instantiated, parameterized andcompiled. Such complexity no doubt would render the entire systemdifficult to use.

In addition to mechanical resource operation variance, other informationcorresponding to a process to be simulated must be specified. Forexample, in addition to interaction between mechanical resources andPLCs, other entities, referred to collectively herein as “thirdentities”, typically interact with the mechanical resources and PLCsduring a process and third entity characteristics need to be modeled.For instance, emergency or “E” stops are routinely provided alongmachine lines which consist of stop buttons, switches, or the like whichcan be activated to cut power off to line stations thereby rendering thestations safe for operator entry. E-stop/PLC interaction is typicallylimited to an activation signal sent to the PLC when an E-stop isactivated. Nevertheless, E-stop activation clearly has a much greateraffect on line operation than simply signaling a PLC. The E-stop affecthas to be modeled to facilitate realistic simulation.

As another instance, a PLC may provide a signal causing a shot pint tobe fired into a position which locks two mechanical devices togetheruntil the pin is subsequently removed via PLC instruction. In this case,the shot pin has characteristics independent of PLC control which affectthe overall process. For instance, even where the process fails for somereason or where an E-stop is used to halt the process, a locking shotpin which locks two devices together remains locked and thatcharacteristic must be modeled.

As still one other instance, many processes require operatorintervention or cooperation. For example, a process may require amachine line operator to load components at a first station,subsequently lock-out, tag-out and enter a third station to check partorientation, un-tag and un-lock the third station and so on. Althoughthese process steps are not controlled by a PLC, these steps affectprocess execution and therefore must be modeled to facilitate realisticprocess simulation.

According to a second embodiment of the inventive simulation aspect,simulation information required for realistic simulation is divided intofirst and second information sets including “control characteristics”and the combination of both “circumstantial characteristics” and thirdentity characteristics. Control characteristics are characteristicswhich, after CA parameterization, are identical for resourcescorresponding to the CA and are independent of other circumstantialconsiderations which affect request execution. For example, in the caseof a SafeBulkHeadClampSet CA, control characteristics include thedevices specified in the CA, resource requests and corresponding I/ocombinations and feedback events and corresponding I/O combinations.From a controls perspective all of these characteristics of resourcescorresponding to a CA are identical.

Circumstantial characteristics, as the name implies, are characteristicswhich may vary for a given CA resource and which affect requestexecution. Circumstantial characteristics may vary with the hardwareused to configure a resource, resource environment, recent resourceactivities, etc. For example, in the case of a clamp, one circumstantialcharacteristic may be that extending speed is dependent uponenvironmental and other circumstantial conditions. For instance,extending speed may vary with humidity and/or temperature. Similarly,extending speed may depend on recent clamp activity. To this end, wherea clamp has recently been stagnant for a period, extending speed may beslower than where a clamp has been active (i.e., extending andcontracting). In addition circumstantial characteristics typically arerelated to hardware used to configure resources. Thus, hardware from onevendor often will have different extending speed characteristics thanhardware from another vendor.

As described above, third entity characteristics include characteristicswhich are related to system hardware, software and system operatorswhich function, at least in part, independent of PLC commands. Thesecharacteristics include the existence of the third entities, how thethird entities respond to PLC commands or interact with mechanicalresources which are controlled by the PLC and so on.

It has been recognized that because of the universal and fundamentalnature of control characteristics, these characteristics can easily bespecified within a CA simulation specification. Moreover, controlcharacteristics can generally be gleaned from non-simulation informationwhich must be specified for other CA purposes such as specifyingcharacteristics required to generate execution code.

It has also been recognized that a core modeling system (CMS) can beused to specify circumstantial characteristics of resources and tospecify third entity characteristics, to combine circumstantial, controland third entity characteristics via various modeling algorithms and to,based on the combined characteristics, facilitate relatively realisticsimulation. Thus, resource characteristics which are essentiallyunchanging from a controls perspective are specified within the CAsimulation specification and all other circumstantial and third entitycharacteristics which affect request execution are specified by the CMS9816.

Referring now to FIGS. 90 and 117, an exemplary CMS 9816 which supportsthis second embodiment of the invention includes a CMS processor 2950,an interface 2948 and a database 2951. Processor 2950 is linked tointerface 2948 via a two way bus 2947 and to database 2951 via a two waybus 2949. Processor 2950 is a standard microprocessor which is capableof performing various functions as described in more detail below.

Initially, database 2951 includes data structure templates (DSTs) 2974.After CMS 9816 imports control characteristics from simulationspecifications the control characteristics are used to populate DTSs andgenerate separate instantiated data structure instances 2953 for eachresource to be simulated. Data structure instantiation is described inmore detail below. Referring still to FIG. 117, a separate DST 2974 isprovided for each simulatable resource type which is included in any CAsupported by ECDB 9810 (see FIG. 90). For example, referring to FIGS. 84and 85, CA 9000 includes six resources (i.e., two valves and fourcylindicators). Herein it is assumed that CMS 9816 cannot simulate valvemovement but can simulate clamp extension and retraction. Therefore,DSTs 2974 do not include a DST which models a valve but do include a DSTwhich models a clamp. Because each of the four cylindicators in CA 9000may be simulated with a similar video clip, only one DST 2974 isrequired to support all four cylindicators.

Referring to FIGS. 117 and 118, an exemplary instantiated data structure2952 is illustrated. While structure 2952 is already instantiated (i.e.,control characteristics have already been included), the generalconfiguration of an exemplary DST can be appreciated by examiningstructure 2952. In this preferred embodiment each DST includes a namefield 2970, a control characteristics field 2971 and a circumstantialcharacteristics field 2972. Name field 1970 and control characteristicsfield 2971 are initially blank. Upon importation of CA information, namefield 2970 is filled with a specific device name. In FIG. 118 field 2970is already filled with device name “1st cylindicator clamp 2506A”.

Despite being initially blank, it is contemplated that field 2971 willhave some structure which is designed to receive imported information.In the present example, referring again to FIG. 88 and 118, it isassumed field 2971 is configured to store a portion of a simulationspecification corresponding to a single clamp resource. For example,referring also to FIGS. 85 and 88, after parameterization, tables 9302and 9304 correspond to the “1st cylindicator clamp 2506A” device andtherefore, if field 2970 specifies 1st cylindicator clamp 2560A, uponimport of CA information, field 2971 is populated with tables 9302 and9304. Tables 9302 and 9304 are illustrated in field 2972.

Referring still to FIG. 118, circumstantial characteristics field 2972includes two sub-fields including a circumstantial variables field 2975and a simulation rule set field 2976. Field 2975 includes a list ofvariables correlated with variable values which correspond toinformation which effects request execution. For example, field 2975 mayinclude a temperature variable, a humidity variable, a stroke speedvariable during extension of a clamp, etc.

Field 2976 includes simulation rules or modeling algorithmscorresponding to requested resource activities. In essence, simulationrules are equations or algorithms which, when an activity is requested,determine how an activity would be executed in the real world andgenerate data useable by CMS processor 2950 to affect realisticsimulation. For example, assume a PLC I/O combination is received by CMS9816 requesting a retract clamp video clip. Simulation rule set 2976 mayinclude a rule which specifies that at one temperature the video clipwill be completed in five seconds and at a relatively cooler temperaturethe clip will be completed in seven seconds. Here it is contemplatedthat a simulation temperature is specified in circumstantial informationsub-field 2975. Thus, referring also to FIG. 117, when a retract I/Ocombination is received, processor 2950 accesses an appropriate rulefrom field 2976, identifies circumstantial information required by therule, retrieves the circumstantial information from field 2975, appliesthe rule to the circumstantial information to generate a video clipspeed signal and then controls video clip speed to facilitate realisticsimulation. Many other simulation rule sets are contemplated.

Referring again to FIG. 117, in addition to including a separate DST2974 for each simulatable resource type included in a CA supported byECDB 9810, data base 2951 also includes a separate DST 2974 for eachthird entity which may be required to interact with PLC and affectprocess operation. The DSTs 2974 corresponding to third entities aredifferent than the DSTs 2974 corresponding to simulatable resources inthat the third entity DSTs 2974 include entity characteristics as wellas software which models entity operation. Referring also to FIG. 121,an exemplary third entity DST 3111 is illustrated which includes anentity name field 3113 and an entity model and characteristics field3115.

Upon compilation of sequenced requests and activities, CA requests andactivities are gleaned to identify third entities which must besupported for simulation purposes. For example, where a CA has beeninstantiated which corresponds to a mechanical resource for firing ashot pin to lock two devices together, the simulation compilerrecognizes the simulation requirement that a third entity data structurecorresponding to a shot pin be instantiated.

Similarly, where an operator activity has been included in a control barchart, upon compilation the simulation compiler identifies therequirement for an operator data structure to be instantiated.

As with the resource DSTs described above it is contemplated that thethird entity DSTs will include a separate DST for each third entitytype. Referring to FIG. 121, upon compilation, when a third entity datastructure is required, the compiler identifies the entity type, selectsan appropriate DST 2974, populates the DST with an entity name in field3113 and more populate other information in field 3115 such as, in thecase of an E-stop, information indicating how the data structure willinterfere with PLC I/O. After compilation, the third entity datastructures are used in conjunction with the resource data structure tofacilitate simulation.

During simulation it is contemplated that clock speed may be modified bya system operator to increase or decrease simulation speed while stillmaintaining relative event duration speeds. Thus, if first and secondstrokes initially require five and ten seconds, respectively, and theclock is slowed down such that the first stroke requires ten seconds,the second stroke would require twenty seconds thereby maintaining therelative durations of the strokes. In this manner relativelyunintersecting simulation can be sped through and more interestingsimulation can be slowed so that nuances can be identified.

Referring again to FIG. 118, generally, a system user will standardizewith specific hardware provided by specific vendors and therefore manysimulation rule sets for a specific user can be set once for aparticular resource and used routinely thereafter. In fact, it iscontemplated that many if not all of the rule sets in field 2976 may beprovided by a hardware manufacturer for installation. In addition, inregulated environments where temperature and humidity is maintained atconstant levels some of the circumstantial variables in field 2975 mayalso be set once and used routinely thereafter.

While many of the rule sets in fields 2976 may be provided bymanufacturers of hardware, variables in field 2975 often will need to bespecified and, in some cases, it may be advantageous to modify thesimulation rule sets in field 2976. To this end, referring again to FIG.117, it is contemplated that interface 2948 is equipped to enable asystem user to access DSTs 2974 and/or separate data structures 2953 tomodify circumstantial variables and/or rule sets in field 2975 and 2976,respectively. For instance, a temperature variable in field 2975 may bemodified to modify a simulation environment. It is also contemplatedthat interface 2948 may be used to globally modify certaincircumstantial variables such as temperature and/or humidity, etc. forall DSTs and all data structures. Any interface known in the computingarts would suffice for these purposes.

Referring again to FIG. 117, upon import of simulation controlcharacteristics a separate data structure 2953 is instantiated for eachsimulatable resource. A complete example of how data structures 2953 aregenerated is helpful.

To this end, referring again to FIGS. 88 and 90, as described above,after CA parameterization and compiling (via compiler 9812),parameterized simulation specifications like specification 9300 result.Referring also to FIG. 85, herein it will be assumed all resources inlogic specification 9002 have been selected via logic specification 9002and therefore parameterized simulation specification 9300 includes eighttables including a separate video table (e.g. 9302) and a separatefeedback table (e.g., 9304) corresponding to each of the fourcylindicators. Moreover, it will be assumed PLC I/O terminals have beenassigned to specific resources for providing I/O requests to resourcesand receiving I/O feedback signals from sensors.

Referring to FIGS. 88, 90, 117 and 119, at processor block 2980processor 2950 receives simulation specifications (e.g. 9300) fromcompiler 9812. At block 2981 processor 2950 identifies a DST (e.g.,2952) for each simulatable resource which is included in each simulationspecification and a DST for each third entity indicated in a simulationspecification or in a sequenced bar chart. For example, as describedabove, simulation specification 9300 (see FIG. 88) includes four (onlytwo shown) simulatable resources (i.e., the clamps corresponding to thefirst through fourth cylindicators) and therefore processor 2950identifies four separate instances of the DST corresponding to a clamp,a separate clamp DST instance for each resource.

Operation of CMS 9816 with respect to each simulatable resource and eachthird entity is similar and therefore, in the interest of simplifyingthis explanation, CMS 9816 operation will only be described in thecontext of the first cylindicator clamp 2506A resource.

With respect to the clamp 2506A resource, at block 2982, processor 2950places the resource name in name field 2970. In addition, at block 2982processor 2950 populates control characteristics field 2971 with videoand feedback tables (i.e., tables 9302 and 9304) corresponding to theclamp 2506A resource. Finally, at block 2983, processor 2950 stores theinstantiated data structure instance. After data structures for eachsimulatable resource in each imported simulation specification have beenstored in database 2951, CMS 9816 is equipped to support relativelyrealistic simulation.

It should be appreciated that after simulation information has beenimported by CMS 9816, the CA has no other function with respect tosimulation. In other words, the CA is a specifying data constructsimulation is handled by CMS 9816.

Referring now to FIG. 120, an exemplary simulation method isillustrated. Referring also to FIGS. 90, 117 and 118, at process block2984 processor 2950 receives a PLC I/O combination requesting a resourceto perform an activity. In this example, it will be assumed the requestis for 1st cylindicator clamp 2506A to retract (e.g., see againcombination 9320 in FIG. 88). When the I/O combination request isreceived, at block 2985 processor 2950 maps the combination into thevideo table associated with the PLC I/O terminals which generated thecombination. In the present example, the combination is mapped into avideo table (e.g., 9302 in FIG. 88) in control characteristics field2971 at block 2985. This mapping enables processor 2950 to identify aretract video clip as the clip to be generated.

After a video clip to be generated is identified, at block 2986,processor 2950 accesses simulation rule set 2976 to identify a rulewhich can be used to identify how circumstantial characteristics affectrequest execution. Also, at block 2986, processor 2950 identifiescircumstantial information required by the identified simulation rulesand retrieves the requested information from circumstantial informationsub-field 2975.

Continuing, at block 2987 processor 2950 applies the identifiedsimulation rules to the retrieved circumstantial information to identifysimulation characteristics. At block 2988 processor 2950 accesses thefeedback table (e.g., see 9304 in FIG. 88) stored in controlcharacteristics field 2971 to determine if any events corresponding to avideo clip should be indicated via feedback I/O to the PLC. If feedbackI/O is to be supported, processor 9816 identifies the video clip eventwhich will trigger the feedback signal(s).

At block 2989 processor 2950 controls movie module 9818 such that thevideo clip is advanced at a speed consistent with a speed correspondingto the circumstantial characteristic's affect on request execution.

Next, at decision block 2990, if feedback events were to be monitoredcontrol passes to block 2991. In the alternative control passes back upto block 2984 and the next PLC I/O combination is received. At block2991, simulation is monitored. At block 2977, when a feedback event(e.g., the end of a clip) is identified, control passes to block 2992where processor 2950 provides feedback I/O to the PLC.

To simulate varying clamp extending speeds it is contemplated that CMS9816 can control frame advance speed of video clips displayed by module9818. Thus, to simulate slow clamp extension CMS 9816 simply slows downframe advance. With a CMS 9816 which can control frame advance, CMS 9816can identify the end of a stroke or device movement associated withfeedback by monitoring frame advance. As in the above example, CMS 9816provides feedback signals to the PLC to indicate monitored conditions.

In another embodiment some circumstantial characteristics may bespecified in a CA simulation specification. For example, consider theexemplary CA described above which specifies a single valve forsupporting anywhere from one to four clamps. Also assume that the speedwith which a valve can extend clamps is dependent upon the number ofclamps which have to be extended (i.e., which are supported) by thevalve. Thus, where the valve supports only one clamp, extension may bemore rapid than where the valve supports four clamps.

In this case, the number of clamps selected for instantiation in a CAclearly affects request execution in the real world and should beaccounted for in virtual simulation. In other words, the number ofclamps selected for instantiation in a CA is a circumstantialcharacteristic which should be included in the CMS modeling algorithmswhich correspond to the clamps. Despite being a circumstantialcharacteristic, it makes sense to include clamp quantity in the CAsimulation specification as clamp quantity is specified during CAparameterization and can be gleaned from the CA. Thus, in this case,when CA simulation specifications are imported by CMS 9816, both controlcharacteristics and at least one circumstantial characteristic areimported and stored in appropriate data structure fields. It iscontemplated that other circumstantial characteristics may also bespecified in a simulation specification.

Thus, it should be appreciated that the simulation aspects of theinventive enterprise control system may be embodied in many differentforms, the underlying inventive concept being that at least someinformation specified in CAS is exported from the CAS and used forgenerating simulation data structures. The data structures are then usedby a CMS to drive a virtual video simulation as a function of PLC I/Ocombinations and to provide feedback to the PLC as simulationprogresses. Hence, CAS are used for specifying and data structures areused for simulation.

The invention has been described above with respect to preferredembodiments. Obviously, modifications and alterations will occur toothers upon reading and understanding the preceding detaileddescription. It is intended that the invention be construed as includingall such modifications and alterations in so far as they come within thescope of the following claims or equivalents thereof. For example, whilesome of the specifications described above are described as beingessentially complete in that little if any additional information isadded to the specifications upon compiling to generate the controltools, it is contemplated that upon compiling information may be addedto virtually any of the specifications, the important aspect of theinvention being that most information required to specify the controltools is provided in the CAS. For instance, while the schematicspecifications described above include compete schematics correspondingto all CDs in a CA, in another embodiment the schematic specificationmay only include information about CA I/O. In this case it is assumedthat a schematic compiler would include schematics for eachschematically displayable component of a CA, each schematic includingI/O terminals. Upon compiling, each CA specifies the schematics requiredto illustrate the mechanical resources associated with the CA and alsolabels I/O terminals with CA I/O. Parameterization still occurs duringCA specification and is reflected in the schematics chosen and I/Olabeling during compilation. Once again, the important aspect is thatinformation which is specified once and can be used for variousspecifying purposes is used several times to reduce the work required toconfigure all of the control tools.

II Previous Specification

This invention relates to electronic programmable controllers foroperating industrial equipment and visualizing the industrialenvironment being controlled. Electronic programmable controllersutilize a programming language to develop control programs to controlindustrial equipment.

Programmable controllers are well-known systems for operating industrialequipment, such as assembly lines and machine tools, in accordance witha stored program. In these controllers, a stored program is executed toexamine the condition of specific sensing devices on the controlledequipment, and to energize or de-energize selected operating devices onthat equipment contingent upon the status of one or more of the examinedsensing devices. The program not only manipulates single-bit input andoutput data representing the state of the sensing and operating devices,but also performs arithmetic operations, timing and counting functions,and more complex processing operations.

One industry that extensively uses programmable controllers is theautomotive industry. In the automotive industry, various automotiveparts are conveyed along machine lines consisting of many consecutiveworkstations. Most workstations include at least one tool that performssome function to alter the characteristics of work pieces as they aredelivered to the station. For example, an unfinished cast engine blockthat requires a plurality of holes, bores, and threads, as well as othermetal-removing procedures, may be provided at the beginning of a machineline that produces finished engine blocks. The machine line may consistof any number of different stations, each station performing a differentprocedure on the unfinished block. An indexer in the form of a transferbar can be arranged to move each block from one station to the nextfollowing a completed process. Typically, at each station the blockwould be clamped prior to any metal-removing operation.

In this type of system, a programmable controller would receive inputsfrom all of the various tools at all of the workstations and wouldprovide activating output signals to synchronize machine operation.During metal-removing periods with the transfer bar out of the way, allof the tools would perform their functions. In between metal-removingperiods during transfer periods, the tools would be parked, the clampsunclamped, and the transfer bar would advance work pieces from onestation to the next.

Industrial controllers are frequently programmed in Ladder Logic (LL)where instructions are represented graphically by “contacts” and “coils”of virtual relays connected and arranged in ladder-like rungs acrosspower rails. LL, with its input contacts and output coils, reflects theemphasis in industrial control on the processing of large amounts ofinput and output data.

LL also reflects the fact that most industrial control is “real time”;that is, an ideal industrial controller behaves as if it were actuallycomposed of multiple relays connected in parallel rungs to provideoutputs in essentially instantaneous response to changing inputs.Present industrial controllers do not, in fact, employ separate parallelrelay-like structures, but instead simulate the parallel operation ofthe relays by means of a conventional Harvard or Von Neumann-typecomputer processor which executes instructions one at a time,sequentially. The practical appearance of parallel operation is obtainedby employing extremely fast processors in the execution of thesequential control program. As each rung is executed, inputs representedby the contacts are read from memory (as obtained from inputs from thecontrolled process or the previous evaluation of coils of other rungs).These inputs are evaluated according to the logic reflected in theconnection of the contacts into one or more branches within the rungs.Contacts in series across a rung represent boolean AND logic whereascontacts in different branches and thus in parallel across the rungrepresent boolean OR logic.

Typically a single output coil at the end of each rung is set or reset.Based on the evaluation of that rung, this setting or resetting isreflected in the writing to memory of a bit (which ultimately becomes anoutput to the industrial process or to another LL rung).

Once a given rung is evaluated the next rung is evaluated and so forth.In the simplest form of LL programming there are no jumps, i.e. allrungs are evaluated in a cycle or “scan” through the rungs. This is incontrast to conventional computer programming where branch and jumpinstructions cause later instructions or groups of instructions to beskipped, depending on the outcome of a test associated with those branchor jump instructions.

While LL is well suited for controlling industrial processes like thosein the automotive industry, LL programming is not an intuitive processand, therefore, requires highly skilled programmers. Where hundreds ofmachine tool movements must be precisely synchronized to provide amachining process, programming in LL is extremely time-consuming. Thetime and relative skill associated with LL programming together accountfor an appreciable percentage of overall costs associated with a controlsystem. In addition, the final step in LL programming is typically alengthy debugging and reworking step that further adds to overall systemcosts.

One way to streamline any type of programming is to provide predefinedlanguage modules, expressed in a language such as LL, which can be usedrepetitively each time a specific function is required. Because of thesimilar types of tools and movements associated with differentmachine-line stations, industrial control would appear to be an idealindustry for such language modules. The predefined logic module approachworks quite well for certain applications, like small parts-materialhandling or simple machining. The reason for this is that the LLrequired for these applications tends to be very simple. In small partsmaterial handling applications the I/O count is low and the interfacesbetween modules are minimal. In fact, the mechanisms are oftenindependent units, decoupled from neighboring mechanisms by part bufferssuch that no signals are required to be exchanged between modules. These“loosely coupled” systems lend themselves to “cut and paste” programmingsolutions.

But the predefined, fixed logic module approach does not work well forother applications, for example metal-removing applications. There aretwo main reasons for this. First, there can be considerable variation inhow components, such as sensors and actuators, combine to produce evensimple mechanisms. Second, processes like metal removing normallyrequires tightly controlled interaction between many individualmechanisms. Exchanging signals called interlocks, between the controllogic modules of the individual mechanism controls the interaction. Theapplication of specific interlocks depends on knowledge of the processand the overall control strategy, information not generally needed, orknowable, when the control logic for each mechanism is defined.

For example, a drill is a typical metal-removing tool used in theautomotive industry. In this example an ideal drill is mounted on acarriage that rides along a rail between two separate limiting positionson a linear axis, an advanced position and a returned position. Twolimit switches, referred to herein as returned and advanced LSs, arepositioned below the carriage and, when tripped, signal that the drillis in the returned and advanced positions, respectively. Two separatedogs (i.e. trigger extensions), an advanced dog and a returned dog,extend downwardly from the bottom of the carriage to trip the LSs whenthe advanced and returned positions are reached, respectively. In theideal case, both LSs may be assumed to be wired in the same “normallyopened” manner, so that electrically speaking they are open whenreleased and closed when triggered. In this ideal case, where thephysical characteristics of the switches are limited, a single LL logicrung can determine when the drill is in the returned position andanother rung can determine when the drill is in the advanced position.Unfortunately, in reality, there are electrically two types of LSs, oneLS type being wired normally opened and the other type wired normallyclosed. Furthermore, any LS can be mechanically installed in atripped-when-activated configuration, or a released-when-activatedconfiguration. All combinations of these types are used for varioustypes of applications. Thus, application requirements may demand controllogic capable of handling any configuration of LS types.

Simple mathematics demonstrates that with two different electrical typesof LSs and two mechanical configurations, there are sixteen possibleconfigurations of a two-position linear slide. Consider the languagemodules required to implement position logic for all theseconfigurations. To accommodate all sixteen-switch configurations, therecould be sixteen different language modules, each containing fixed LLlogic, and each named for the case it could handle. In this case, therewould be duplicate logic under different names. Alternatively, fourunique language modules could be provided, but then the user would havedifficulty identifying which of the sixteen physical configurations thatthe four modules could handle.

Clearly, even for a simple drill mounted on a two position linear slide,application variables make it difficult to provide a workable library offixed language modules. Adding more switches to the linear slide onlyincreases, to an unmanageable level, the number of language modulesrequired in the library.

Moreover, the contents of a complete language module for a drill mustalso consider other variables. These variables include, for example, thenumber and type of actuators required; the type of spindle, if any;whether or not a bushing plate is required; what type of conveyor isused; whether or not the drill will include an operator panel to enablelocal control. If an operator panel is included, what type of controls(i.e. buttons, switches and indicator lights) are required, just to namea few. Each tool variable increases the required number of unique LLmodules by more than a factor of two, which makes it difficult at bestto provide an LL library module for each possible drill configuration.

Taking into account the large number of different yet possiblemachine-line tools, each tool having its own set of variables, the taskof providing an all-encompassing library of fixed language modulesbecomes impractical. Even if such a library could be fashioned, the taskof choosing the correct module to control a given tool would probably bemore difficult than programming the required LL logic from scratch.

For these reasons, although attempts have been made at providingcomprehensive libraries of fixed language modules, none has provenparticularly successful and much LL programming is done from scratch.

Manufacturing customers have long desired an integrated environment forgenerating an initial design schematic specifying a functionaldescription of a manufacturing environment without the need forspecifying product and manufacturing details. The system is providedwith a designer studio that utilizes a common database ofpre-architected modules to integrate a total system solution for theenterprise. The pieces of this system include design, simulation,implementation and maintenance information for both product andmanufacturing.

The foregoing problems are overcome in an illustrative embodiment of theinvention in which a system for designing, simulating, implementing andmaintaining an enterprise solution for an enterprise is disclosed. Thesystem includes software that controls an enterprise. The softwareincludes one or more components for controlling one or more aspects ofan industrial environment with code that creates a database ofcomponents, each of the components containing control, diagnostic andresource information pertaining to enterprise resources utilized in theindustrial environment. The software system also generates code thatcontrols resources comprising cognitive and timing information thatsynchronizes events throughout the enterprise. The database ofcomponents includes code that updates the database to reflect changes inthe enterprise that manage the design, simulation, implementation andmaintenance of a manufacturing enterprise utilizing the database ofcomponents.

The system software defines and illustrates the electrical, pneumatic,hydraulic, logic, diagnostics, external behavior, controlled resourcesand safety elements of an enterprise control system. The elements of thecontrol system are encapsulated in objects of an object-orientedframework within a control assembly. The control assembly is thefundamental building block for providing object-oriented control of theenterprise.

A control assembly component is a deployable control subsystem thatprovides an interface using a common object model that is configurable.The control assembly exposes an interface of viewable elements. Thelogic associated with the interface allows the interface designer toquery the control assembly to obtain the viewable elements and retrievethe properties of these viewable elements.

A preferred embodiment of a system in accordance with the presentinvention is preferably practiced in the context of a personal computersuch as an IBM, Apple Macintosh or UNIX based computer. A representativehardware environment is depicted in FIG. 1A, which illustrates a typicalhardware configuration of a workstation in accordance with a preferredembodiment having a central processing unit 10, such as amicroprocessor, and a number of other units interconnected via a systembus 12. The workstation shown in FIG. 1A includes a Random Access Memory(RAM) 14, Read Only Memory (ROM) 16, an I/O adapter 18 for connectingperipheral devices such as disk storage units 20 to the bus 12, a userinterface adapter 22 for connecting a keyboard 24, a mouse 26, a speaker28, a microphone 32, and/or other user interface devices such as a touchscreen (not shown) to the bus 12, communication adapter 34 forconnecting the workstation to a communication network (e.g., a dataprocessing network) and a display adapter 36 for connecting the bus 12to a display device 38. The workstation typically has resident thereonan operating system such as the Microsoft Win/95 NT Operating System(OUTSTANDING) or UNIX OUTSTANDING. Those skilled in the art willappreciate that the present invention may also be implemented onplatforms and operating systems other than those mentioned.

A preferred embodiment is written using JAVA, C, and the C++ languageand utilizes object oriented programming methodology. Object orientedprogramming (OOP) has become increasingly used to develop complexapplications. As OOP moves toward the mainstream of software design anddevelopment, various software solutions will need to be adapted to makeuse of the benefits of OOP. A need exists for these principles of OOP tobe applied to a messaging interface of an electronic messaging systemsuch that a set of OOP classes and objects for the messaging interfacecan be provided.

OOP is a process of developing computer software using objects,including the steps of analyzing the problem, designing the system, andconstructing the program. An object is a software package that containsboth data and a collection of related structures and procedures. Sinceit contains both data and a collection of structures and procedures, itcan be visualized as a self-sufficient component that does not requireother additional structures, procedures or data to perform its specifictask. OOP, therefore, views a computer program as a collection oflargely autonomous components, called objects, each of which isresponsible for a specific task. This concept of packaging data,structures, and procedures together in one component or module is calledencapsulation.

In general, OOP components are reusable software modules that present aninterface that conforms to an object model and which are accessed atrun-time through a component integration architecture. A componentintegration architecture is a set of architecture mechanisms which allowsoftware modules in different process spaces to utilize each otherscapabilities or functions. This is generally done by assuming a commoncomponent object model on which to build the architecture.

It is worthwhile to differentiate between an object and a class ofobjects at this point. An object is a single instance of the class ofobjects, which is often just called a class. A class of objects can beviewed as a blueprint, from which many objects can be formed.

OOP allows the programmer to create an object that is a part of anotherobject. For example, the object representing a piston engine is said tohave a composition-relationship with the object representing a piston.In reality, a piston engine comprises a piston, valves and many othercomponents; the fact that a piston is an element of a piston engine canbe logically and semantically represented in OOP by two objects.

OOP also allows creation of an object that “depends from” anotherobject. If there are two objects, one representing a piston engine andthe other representing a piston engine wherein the piston is made ofceramic, then the relationship between the two objects is not that ofcomposition. A ceramic piston engine does not make up a piston engine.Rather it is merely one kind of piston engine that has one morelimitation than the piston engine; its piston is made of ceramic. Inthis case, the object representing the ceramic piston engine is called aderived object, and it inherits all of the aspects of the objectrepresenting the piston engine and adds further limitation or detail toit. The object representing the ceramic piston engine “depends from” theobject representing the piston engine. The relationship between theseobjects is called inheritance.

When the object or class representing the ceramic piston engine inheritsall of the aspects of the objects representing the piston engine, itinherits the thermal characteristics of a standard piston defined in thepiston engine class. However, the ceramic piston engine object overridesthese ceramic specific thermal characteristics, which are typicallydifferent from those associated with a metal piston. It skips over theoriginal and uses new functions related to ceramic pistons. Differentkinds of piston engines will have different characteristics, but mayhave the same underlying functions associated with it (e.g., how manypistons in the engine, ignition sequences, lubrication, etc.). To accesseach of these functions in any piston engine object, a programmer wouldcall the same functions with the same names, but each type of pistonengine may have different/overriding implementations of functions behindthe same name. This ability to hide different implementations of afunction behind the same name is called polymorphism and it greatlysimplifies communication among objects.

With the concepts of composition-relationship, encapsulation,inheritance and polymorphism, an object can represent just aboutanything in the real world. In fact, our logical perception of thereality is the only limit on determining the kinds of things that canbecome objects in object-oriented software. Some typical categories areas follows:

Objects can represent physical objects, such as automobiles in atraffic-flow simulation, electrical components in a circuit-designprogram, countries in an economics model, or aircraft in anair-traffic-control system.

Objects can represent elements of the computer-user environment such aswindows, menus or graphics objects.

An object can represent an inventory, such as a personnel file or atable of the latitudes and longitudes of cities.

An object can represent user-defined data types such as time, angles,and complex numbers, or points on the plane.

With this enormous capability of an object to represent just about anylogically separable matters, OOP allows the software developer to designand implement a computer program that is a model of some aspects ofreality, whether that reality is a physical entity, a process, a system,or a composition of matter. Since the object can represent anything, thesoftware developer can create an object which can be used as a componentin a larger software project in the future.

If 90% of a new OOP software program consists of proven, existingcomponents made from preexisting reusable objects, then only theremaining 10% of the new software project has to be written and testedfrom scratch. Since 90% already came from an inventory of extensivelytested reusable objects, the potential domain from which an error couldoriginate is 10% of the program. As a result, OOP enables softwaredevelopers to build objects out of other, previously built, objects.

This process closely resembles complex machinery being built out ofassemblies and sub-assemblies. OOP technology, therefore, makes softwareengineering more like hardware engineering in that software is builtfrom existing components, which are available to the developer asobjects. All this adds up to an improved quality of the software as wellas an increased speed of its development.

Programming languages are beginning to fully support the OOP principles,such as encapsulation, inheritance, polymorphism, andcomposition-relationship. With the advent of the C++ language, manycommercial software developers have embraced OOP. C++ is an OOP languagethat offers a fast, machine-executable code. Furthermore, C++ issuitable for both commercial-application and systems-programmingprojects. For now, C++ appears to be the most popular choice among manyOOP programmers, but there is a host of other OOP languages, such asSmalltalk, common lisp object system (CLOS), and Eiffel. Additionally,OOP capabilities are being added to more traditional popular computerprogramming languages such as Pascal.

The benefits of object classes can be summarized, as follows:

Objects and their corresponding classes break down complex programmingproblems into many smaller, simpler problems.

Encapsulation enforces data abstraction through the organization of datainto small, independent objects that can communicate with each other.Encapsulation protects the data in an object from accidental damage, butallows other objects to interact with that data by calling the object'smember functions and structures.

Subclassing and inheritance make it possible to extend and modifyobjects through deriving new kinds of objects from the standard classesavailable in the system. Thus, new capabilities are created withouthaving to start from scratch.

Polymorphism and multiple inheritance make it possible for differentprogrammers to mix and match characteristics of many different classesand create specialized objects that can still work with related objectsin predictable ways.

Class hierarchies and containment hierarchies provide a flexiblemechanism for modeling real-world objects and the relationships amongthem.

Libraries of reusable classes are useful in many situations, but theyalso have some limitations. For example:

Complexity. In a complex system, the class hierarchies for relatedclasses can become extremely confusing, with many dozens or evenhundreds of classes.

Flow of control A program written with the aid of class libraries isstill responsible for the flow of control (i.e., it must control theinteractions among all the objects created from a particular library).The programmer has to decide which functions to call at what times forwhich kinds of objects.

Duplication of effort. Although class libraries allow programmers to useand reuse many small pieces of code, each programmer puts those piecestogether in a different way. Two different programmers can use the sameset of class libraries to write two programs that do exactly the samething but whose internal structure (i.e., design) may be quitedifferent, depending on hundreds of small decisions each programmermakes along the way. Inevitably, similar pieces of code end up doingsimilar things in slightly different ways and do not work as welltogether as they should.

Class libraries are very flexible. As programs grow more complex, moreprogrammers are forced to reinvent basic solutions to basic problemsover and over again. A relatively new extension of the class libraryconcept is to have a framework of class libraries. This framework ismore complex and consists of significant collections of collaboratingclasses that capture both the small scale patterns and major mechanismsthat implement the common requirements and design in a specificapplication domain. They were first developed to free applicationprogrammers from the chores involved in displaying menus, windows,dialog boxes, and other standard user interface elements for personalcomputers.

Frameworks also represent a change in the way programmers think aboutthe interaction between the code they write and code written by others.In the early days of procedural programming, the programmer calledlibraries provided by the operating system to perform certain tasks, butbasically the program executed down the page from start to finish, andthe programmer was solely responsible for the flow of control. This wasappropriate for printing out paychecks, calculating a mathematicaltable, or solving other problems with a program that executed in justone way.

The development of graphical user interfaces began to turn thisprocedural programming arrangement inside out. These interfaces allowthe user, rather than program logic, to drive the program and decidewhen certain actions should be performed. Today, most personal computersoftware accomplishes this by means of an event loop that monitors themouse, keyboard, and other sources of external events and calls theappropriate parts of the programmer's code according to actions that theuser performs. The programmer no longer determines the order in whichevents occur. Instead, a program is divided into separate pieces thatare called at unpredictable times and in an unpredictable order. Byrelinquishing control in this way to users, the developer creates aprogram that is much easier to use. Nevertheless, individual pieces ofthe program written by the developer still call libraries provided bythe operating system to accomplish certain tasks, and the programmermust still determine the flow of control within each piece after it'scalled by the event loop. Application code still “sits on top of” thesystem.

Even event loop programs require programmers to write a lot of code thatshould not need to be written separately for every application. Theconcept of an application framework carries the event loop conceptfurther. Instead of dealing with all the nuts and bolts of constructingbasic menus, windows, and dialog boxes and then making these things allwork together, programmers using application frameworks start withworking application code and basic user interface elements in place.Subsequently, they build from there by replacing some of the genericcapabilities of the framework with the specific capabilities of theintended application.

Application frameworks reduce the total amount of code that a programmerhas to write from scratch. However, because the framework is really ageneric application that displays windows, supports copy and paste, andso on, the programmer can also relinquish control to a greater degreethan event loop programs permit. The framework code takes care of almostall event handling and flow of control. The programmer's code is calledonly when the framework needs it (e.g., to create or manipulate aproprietary data structure).

A programmer writing a framework program not only relinquishes controlto the user (as is also true for event loop programs), but alsorelinquishes the detailed flow of control within the program to theframework. This approach allows the creation of more complex systemsthat work together in interesting ways, as opposed to isolated programs,having custom code, being created over and over again for similarproblems.

Thus, as is explained above, a framework basically is a collection ofcooperating classes that make up a reusable design solution for a givenproblem domain. It typically includes objects that provide defaultbehavior (e.g., for menus and windows). Programmers use it by inheritingsome of that default behavior and overriding other behavior so that theframework calls application code at the appropriate times.

There are three main differences between frameworks and class libraries:

Behavior versus protocol Class libraries are essentially collections ofbehaviors that you can call when you want those individual behaviors inyour program. A framework on the other hand, provides not only behaviorbut also the protocol or set of rules that govern the ways in whichbehaviors can be combined, including rules for what a programmer issupposed to provide versus what the framework provides.

Call versus override. With a class library, the class member is used toinstantiate objects and call their member functions. It is possible toinstantiate and call objects in the same way with a framework (i.e., totreat the framework as a class library), but to take full advantage of aframework's reusable design, a programmer typically writes code thatoverrides and is called by the framework. The framework manages the flowof control among its objects. Writing a program involves dividingresponsibilities among the various pieces of software that are called bythe framework rather than specifying how the different pieces shouldwork together.

Implementation versus design. With class libraries, programmers reuseonly implementations, whereas with frameworks, they reuse design. Aframework embodies the way a family of related programs or pieces ofsoftware work. It represents a generic design solution that can beadapted to a variety of specific problems in a given domain. Forexample, a single framework can embody the way a user interface works,even though two different user interfaces created with the sameframework might solve quite different interface problems.

Thus, through the development of frameworks for solutions to variousproblems and programming tasks, significant reductions in the design anddevelopment effort for software can be achieved. HyperText MarkupLanguage (HTML) is utilized to implement documents on the Internettogether with a general-purpose secure communication protocol for atransport medium between the client and the merchant. HTML is a simpledata format used to create HyperText documents that are portable fromone platform to another. HTML documents are Standard Generalized MarkupLanguage (SGML) documents with generic semantics that are appropriatefor representing information from a wide range of domains. HTML has beenin use by the World-Wide Web global information initiative since 1990.HTML is an application of ISO Standard 8879:1986 Information ProcessingText and Office Systems; SGML.

To date, Web development tools have been limited in their ability tocreate dynamic Web applications which span from client to server andinteroperate with existing computing resources. Until recently, HTML hasbeen the dominant technology used in development of Web-based solutions.However, HTML has proven to be inadequate in the following areas:

Poor performance;

Restricted user interface capabilities;

Can only produce static Web pages;

Lack of interoperability with existing applications and data; and

Inability to scale.

Sun Microsystem's Java language solves many of the client-side problemsby:

Improving performance on the client side;

Enabling the creation of dynamic, real-time Web applications; and

Providing the ability to create a wide variety of user interfacecomponents.

With Java, developers can create robust User Interface (UI) components.Custom “widgets” (e.g. real-time stock tickers, animated icons, etc.)can be created, and client-side performance is improved. Unlike HTML,Java supports the notion of client-side validation, offloadingappropriate processing onto the client for improved performance.Dynamic, real-time Web pages can be created. Using the above-mentionedcustom UI components, dynamic Web pages can also be created.

Sun's Java language has emerged as an industry-recognized language for“programming the Internet.” Sun defines Java as: “a simple,object-oriented, distributed, interpreted, robust, secure,architecture-neutral, portable, high-performance, multithreaded,dynamic, buzzword-compliant, general-purpose programming language. Javasupports programming for the Internet in the form ofplatform-independent Java applets.” Java applets are small, specializedapplications that comply with Sun's Java Application ProgrammingInterface (API) allowing developers to add “interactive content” to Webdocuments (e.g. simple animations, page adornments, basic games, etc.).Applets execute within a Java-compatible browser (e.g. NetscapeNavigator) by copying code from the server to client. From a languagestandpoint, Java's core feature set is based on C++. Sun's Javaliterature states that Java is basically “C++, with extensions fromObjective C for more dynamic method resolution.”

Another technology that provides similar function to JAVA is provided byMicrosoft and ActiveX Technologies, to give developers and Web designerswherewithal to build dynamic content for the Internet and personalcomputers. ActiveX includes tools for developing animation, 3D virtualreality, video and other multimedia content. The tools use Internetstandards, work on multiple platforms, and are being supported by over100 companies. The group's building blocks are called ActiveX Controls,small, fast components that enable developers to embed parts of softwarein HyperText markup language (HTML) pages. ActiveX Controls work with avariety of programming languages including Microsoft Visual C++, BorlandDelphi, Microsoft Visual Basic programming system and J++. ActiveXTechnologies also includes ActiveX Server Framework, allowing developersto create server applications. One of ordinary skill in the art willreadily recognize that ActiveX could be substituted for JAVA withoutundue experimentation to practice the invention.

A ladder logic editor in accordance with a preferred embodiment allows auser to program and display a PLC's ladder program as illustrated inFIG. 1B. The program utilized is the RSLogix program manufactured andsold by the assignee of the subject patent. The programming toolprovides a graphical user interface to facilitate rapid prototype andproduction of programs for execution in a PLC. Information is organizedin rungs of sequential instructions organized in the shape of a ladder(ladder logic). The tool allows an operator to determine if a particularhardware entity is in a particular state and thereby allows the operatorto exercise complete control over the environment. The RSLogix programtool supports traditional ladder logic and nontraditional controllanguages such as C, C++ and Java. It takes advantage of a current andfuture pool of developing control programmers and supports a large baseof legacy applications. The emphasis of this tool is to improve aprogrammer's productivity in entering control code.

Although tools for programming a particular PLC to perform a particulartask utilizing ladder logic exist, an integrated solution for designing,simulating, implementing and maintaining both product and manufacturinginformation across an enterprise has not existed until now. Anenterprise wide solution is important to achieve important customergoals such as reducing commissioning time by allowing validation of thedesign before investing significant resources in implementing a designthat may not address customer requirements. A preferred embodiment alsoprovides consistent information across the enterprise without requiringredundant information. A single database is employed to capture andmaintain design, simulation, implementation and maintenance informationconcerning the enterprise wide solution. The single database alsofacilitates consistent design and implementation details since changesin the product and process are stored as changes to the control areeffected.

Another customer goal is to reduce downtime. This goal is addressed inaccordance with a preferred embodiment by the architecture of thesystem. In accordance with a preferred embodiment, each component isdesigned with data and logic associated with various pieces ofinformation that are critical to the operation of the component and thesystem. One set of information that is designed into each component isthe logic and data for diagnosing problems with the component. Thus asmodels of the enterprise are built utilizing these components, thediagnostic system is automatically constructed based on carefullythought-out information for each of the components. Thus, as a sensorlevel measuring proper performance levels falls below an approvedthreshold, information about the particular component and the level isavailable with non-ambiguous data that can be communicated back to theoperator to solve the problem.

Today, major manufacturers are digitally integrating their design,simulation, implementation and maintenance manually and also integratingtheir processes and the processes of their suppliers. They are beingdriven to a solution in accordance with a preferred embodiment becausedesign and manufacturing processes of major manufacturers are complexand the scale of their operations is enormous. Complex, large scaleintegration requires that all design, simulation, implementation andmaintenance information must be accessible digitally across anenterprise in a common format. Each enterprise design domain (e.g.,part, machine, control, and diagnostic) must be modeled in a computerrepresentation containing syntax (format of the domain representation)and semantics (meaning of the domain representation). Finally, anintegrated data model in accordance with a preferred embodiment must beadhered to by the entire enterprise to establish mappings between thedomains and their respective representations. The resultant solutioneliminates the barriers that traditionally exist between the design andmanufacturing domains.

FIG. 2 illustrates an enterprise solution in accordance with a preferredembodiment. In today's environment a body engineer designs a doorassembly based on experience of parts, structural knowledge and weldinginformation. This information is given to a machine or tool engineer todesign a detailed process and tools for manufacturing the door based onother experience and existing manufacturing information. Then, thecontrol engineer must design the sensor/actuator relationships toimplement the manufacture of the door in an automated environment basedon experience. Timing diagrams, causal relationships, a Human MachineInterface (HMI), input/output tables, safety and diagnostic informationmust be integrated into the design after the fact and control logic mustbe generated to execute on the PLCs to implement the manufacturingprocesses. Then the control environment including clamps, hydraulics,electrical, robots and transport systems must be integrated with the PLCto begin testing the feasibility of the architecture. Resultant changesand additional diagnostic information are cycled through as time marcheson. Finally, the process engineer translates management numbers forfinished goods into a high-level process of actions and resources basedon acquired experience and provides raw materials and goals to drive themanufacturing process. Currently, without the subject invention, thisprocess can literally take years.

Enterprise wide controls in accordance with a preferred embodiment arenecessary to organize and manage the increasing amount of informationnecessary to facilitate effective control of machines, processes andproducts. Management of this information includes validation statisticsfor the manufacturing enterprise, diagnostics and an organizationalstructure that avoids redundancies to avoid storage and executioninefficiencies. Feedback of control information into the design systemis also critical to maintain a current view of the enterprise at alltimes and to synchronize information so that all engineers are literallysinging out of the same hymnal.

Enterprise wide controls construct a control system within anintegrated, enterprise-wide model that reuses control assemblies fromexisting subscription libraries and linkages between products,processes, machine and control models. Controls, diagnostics and HMIcode from the control system model database is systematic with fullcoverage diagnostics from the start of the process to completion. Thecode is always consistent with product, process, machine and controlmodels. The enterprise wide control system generates code that isutilized to animate simulation and subsequent production displays with agraphical depiction at various levels of hierarchical detail of theenterprise. An operator can zoom in to observe particular areas based oninformation from the enterprise to control large parts of the enterprisefrom a central control station.

An Enterprise Control Database (ECDB) acts as a single repository ofenterprise information containing instantaneous access to engineeringbill-of-material (EBOM) data for parts and assembly of parts as well asmaintaining manufacturing bill-of-material (MBOM) which tracks thefinished goods inventory as it is built. Factory service records arealso captured and stored in the database as they occur. Controlassemblies and control components are also stored in the ECDB.Diagnostic assemblies and diagnostic components are also stored with thecontrol system configuration (processor, racks, networks and wiringdiagrams).

A control component in accordance with a preferred embodiment is amachine part that either accepts inputs from the control system and/orgenerates outputs to the control system. A control assembly (descriptiveclass) is a configuration of control components and the defined set ofstates the control component can attain. The control assembly generatesadditional machine resource requirements and requests to the mechanicaldesign system. A schematic of each control assembly is stored in theECDB.

A control assembly is also responsible for performing one or moreactions defined as a discrete action class. For example, a class actionmay be an input signal that requests an action in an external word, oran input signal that confirms completion of a particular task. A classaction in accordance with a preferred embodiment can appear as a bar ona barchart. A class input, often referred to by old-time controlengineers as a digital input or D1 could be an input signal indicativeof a state in the enterprise.

For example, when a heater reaches a threshold temperature, the processcan proceed. Other examples include emergency stop, part present or amode switch. Typically, class inputs are utilized as safeties,interlocks, cycle enablers or diagnostic inputs. A class output, digitaloutput (D0) is an output signal to the enterprise to signal information.For example, turning on a cycle complete light. These entities readilylend themselves to implementation in an object-oriented abstraction asrealizable classes for use in instantiating object instances of theclasses. Examples of realizable classes in accordance with a preferredembodiment include PartPresent, ControlRobot, DumpSet, PinSet andSafeBulkHeadClampSet.

FIG. 3 illustrates a database entry for a SafeBulkHeadClampSet inaccordance with a preferred embodiment. Each of the control valves,cylinders and other clamp information is stored in a single recordcompletely defining the clamp and its characteristics to enable it toopen and close on a target assembly effectively and safely. In addition,the database keeps track of how many catalog entries have incorporatedthis physical component into their design.

A diagnostic component in accordance with a preferred embodiment is anelectrical, mechanical or pneumatic component that has no directconnection to the control system and is architected into the componentfor diagnostic purposes.

A diagnostic assembly (descriptive class) is a configuration of controlcomponents and diagnostic component in which the configuration isdetermined by the causal relationships that are useful for diagnosticpurposes. Additional machine resource requirements may be required togenerate requests to the mechanical design system.

FIG. 4 is a block diagram of the enterprise system in accordance with apreferred embodiment. A CATIA design station 400 utilizes a CNEXTinterface to transmit design information, activities (process steps) andresources (a description of the tooling machine) to the EnterpriseDatabase (ECDB) 410. The design information is a picture, for example adoor welding station, with robot welders, clamps, a PLC and a transportmechanism. The ECDB receives information from the CATIA CNEXT interfacedefining activities and resources that will be necessary to build thestation.

The ECDB integrates information from the CATIA CAD package 400, DesignerStudio 430, code generation 440, final code 470 and the causal modelsubsystem 450. The activities and information that come from the CATIAinterface 400 are created by a mechanical tool designer and they omitkey information that comes from the control designer.

The Designer Studio 430 completes the activity and resource informationin the ECDB 410 utilizing a graphical user interface that is C++ basedJava code. The key organizing concept throughout an enterprise system inaccordance with a preferred embodiment is CONTROL ASSEMBLY. Controlassembly refers to utilizing a component based software assembly just ashardware designers utilize chip assemblies in hardware design andmanufacture. A template type building block architecture is enabled fordesigning and managing enterprises. Software and hardware components arecataloged in the ECDB 410 for maximal reuse of the components. The ECDB410 is a relational database implemented in a Microsoft Access productin accordance with a preferred embodiment. One of ordinary skill in theart will readily comprehend that other databases (relational or network)could readily be substituted without undue experimentation.

Once the database is populated, then information from the database isutilized to construct a code generation data structure 440 in a treeformat as described later in detail. The database is also utilized tocreate the causal model 450. The causal model 450 is utilized to enablesystem diagnostics. The causal model is a LISP knowledge base.

The causal model 450 and the code generation data structure 440 isutilized as input for the PanelView Editor to automatically generate theoperator's interface. Old code modified to work with new interface. ThePanelView Editor also generates control code in the form of ladderlogic. The causal model 450 generates diagnostic ladder logic that ismixed with the control code from the code generation 440 to create thefinal code 470 for controlling and monitoring the enterprise. The ladderlogic is downloaded to the PLC 472 for controlling the enterprise.

The relay ladder logic code for control and diagnostics are merged bymultiplexor code. The PanelView Editor generates code that enables theuser interface to display graphical depictions of what is happening inthe process and also to display diagnostic output.

The ECDB is also used by the RSWire schematic processor 480 to createschematic depictions of the sensor environment and transmit theschematic results back to the CNEXT system in CATIA where the tooldesign was also performed. This architecture, in accordance with apreferred embodiment, facilitates the location of changes in theprocessing efficiently which streamlines location of modificationlocations in the stations and control logic downstream.

The output from the ECDB is also provided to a schematic detailingpackage (RSWire) which enables a control engineer to decide where eachof the clamps on a welding machine should be and locates valves,pneumatic piping etc. on the schematic detailing. A control engineer canplace the cylinders and the schematic is generated from this informationfor wiring, piping and/or HVAC layout. Components are predesigned thatenable design of an enterprise wide control system in accordance with apreferred embodiment of the invention. Control assemblies are merelyobjects encapsulating data and functions for performing standard controlfunctions. Another set of macros are architected in accordance with apreferred embodiment for wiring diagrams that are componentized.

What we do for simulation is to load the PLC code into a PLC simulatorSOFTLOGIX 5 (A/B product). This is utilized to drive a CAD simulator.The PLC Simulator & CAD Simulator utilize information from the CATIAdatabase and the ECDB in accordance with a preferred embodiment. Then,when the code has been debugged, it is downloaded to the PLC 472 forproduction testing and ultimately running the enterprise.

The final schematics generated by the schematic tool 480 are ultimatelysent back to CATIA 400 utilizing the standard CNEXT interface. Thisfeedback mechanism is necessary to synchronize the CATIA database withthe ECDB 410. This feedback mechanism also facilitates the addition ofgeometry to the original CAD drawings.

The database design of the ECDB includes tables that map activities intoinformation appearing in the tables that is imported from the existingCATIA drawings. The resource import table is called StructuralComponents. It is implemented in accordance with a preferred embodimentin an ACCESS database with a record of the following structure:

U:˜1VCM980330a.mdb Monday, March 30, 1998 Table: Structural ComponentsProperties Date Created: 3/6/98 11:18:49 AM Def. Updatable: True LastUpdated: 3/30/98 2:14:37 PM OrderByOn: True RecordCount: 56 Columns NameType Size StructuralComponentID Number (Long) 4 AllowZeroLength: FalseAttributes: Fixed Size, Auto-Increment Collating Order: GeneralColumnHidden: False ColumnOrder: Default ColumnWidth: Default OrdinalPosition: 1 Required: False Source Field: StructuralComponentID SourceTable: StructuralComponents ExtID Text 255 AllowZeroLength: FalseAttributes: Variable Length Collating Order: General ColumnHidden: FalseColumnOrder: Default ColumnWidth: 8268 Description: unique id for thisspatial component DisplayControl: Text Box Ordinal Position: 2 Required:False Source Field: ExtID Source Table: StructuralComponents Label Text50 AllowZeroLength: False Attributes: Variable Length Collating Order:General ColumnHidden: False ColumnOrder: Default ColumnWidth: 1620Description: label to show on graphic renditions of this componentDisplayControl: Text Box Ordinal Position: 3 Required: False SourceField: Label Source Table: StructuralComponents Class Text 50AllowZeroLength: False Attributes: Variable Length Collating Order:General ColumnHidden: False ColumnOrder: Default ColumnWidth: 1545Description: class of spatial components to which this instance belongs-determines what types of control components can be in this spatialcomponent DisplayControl: Text Box Ordinal Position: 4 Required: FalseSource Field: Class Source Table: StructuralComponents WorkCellID Number(Long) 4 AllowZeroLength: False Attributes: Fixed Size Bound Column: 1Caption: WorkCell Collating Order: General Column Count: 1 Column Heads:False Column Widths: 1440 ColumnHidden: False ColumnOrder: DefaultColumnWidth: 1140 Decimal Places: Auto Default Value: 0 Description:workcell that this component is part of-either this field or the nextone is mandatory DisplayControl: Combo Box Limit To List: False ListRows: 8 List Width: 1440twip Ordinal Position: 5 Required: False RowSource Type: Table/Query Row Source: SELECT DISTINCTROW[WorkCell].[WorkCellID] FROM [WorkCell]; Source Field: WorkCellID SourceTable: StructuralComponents PartOf Text 255 AllowZeroLength: FalseAttributes: Variable Length Collating Order: General ColumnHidden: FalseColumnOrder: Default ColumnWidth: 5985 Description: other spatialcomponent that this component is part of-if this field is 0, it is a toplevel component DisplayControl: Text Box Ordinal Position: 6 Required:True Source Field: PartOf Source Table: StructuralComponents CommentMemo AllowZeroLength: False Attributes: Variable Length Collating Order:General ColumnHidden: False ColumnOrder: Default ColumnWidth: DefaultOrdinal Position: 7 Required: False Source Field: Comment Source Table:StructuralComponents Relationships Reference26 StructuralComponentsControlAssemblyInstance StructuralComponentID StructuralComponentIDAttributes: Not Enforced Attributes: One-To-Many Reference27StructuralComponents PCCInstanceElements StructuralComponentIDStructuralComponentsID Attributes: Not Enforced Attributes: One-To-ManyTable Indexes Name Number of Fields PrimaryKey 1 Clustered: FalseDistinct Count: 56 Foreign: False Ignore Nulls: False Name: PrimaryKeyPrimary: True Required: True Unique: True Fields: StructuralComponentID,Ascending SpaceComponentID 1 Clustered: False Distinct Count: 56Foreign: False Ignore Nulls: False Name: SpaceComponentID Primary: FalseRequired: False Unique: False Fields: ExtID, AscendingStructuralComponentsID 1 Clustered: False Distinct Count: 56 Foreign:False Ignore Nulls: False Name: StructuralComponentsID Primary: FalseRequired: False Unique: False Fields: StructuralComponentID, AscendingWorkCellID 1 Clustered: False Distinct Count: 1 Foreign: False IgnoreNulls: False Name: WorkCellID Primary: False Required: False Unique:False Fields: WorkCellID, Ascending User Permissions ACR admin ALA ALA2BJB CPI Group Permissions Admins Guests LETTERS MODIFY READ ONLY REPAIRUsers Items that utilize the control assembly catalog have the followingstructure: Table: ControlAssemblyCatalog Properties Date Created:10/22/97 1:25:38 PM Def. Updatable: True Description: CUnit stands for“control unit” Last Updated: 3/30/98 1:45:32 PM These are the generictypes of assemblies that are relevant for control. The description onlyspecifies how to interact with assembly from a control standpoint; itdoesn't say how the instance will be used. OrderByOn: False RecordCount:Columns Name Type Size ControlAssemblyCatalogID 4 Number (Long)AllowZeroLength: False Attributes: Fixed Size, Auto-Increment CollatingOrder: General ColumnHidden: False ColumnOrder: Default ColumnWidth:1092 Description: unique idenitifier for the component structure OrdinalPosition: 1 Required: False Source Field: ControlAssemblyCatalogIDSource Table: ControlAssemblyCatalog Label Text 25 AllowZeroLength:False Attributes: Variable Length Collating Order: General ColumnHidden:False ColumnOrder: Default ColumnWidth: Default Description: humanreadable name for the component structure DisplayControl: Text BoxOrdinal Position: 2 Required: False Source Field: Label Source Table:ControlAssemblyCatalog DecompositionType Text 50 AllowZeroLength: FalseAttributes: Variable Length Bound Column: 1 Collating Order: GeneralColumn Count: 1 Column Heads: False Column Widths: 1440 ColumnHidden:False ColumnOrder: Default ColumnWidth: 1944 Description: whether thisassembly can be broken down into discrete components or whether it is asingle object like a robot or a PanelView. DisplayControl: Combo BoxLimit To List: False List Rows: 8 List Width: 1440twip Ordinal Position:3 Required: False Row Source Type: Value List Row Source: “Virtual”;“Physical”; “Programmable” Source Field: DecompositionType Source Table:ControlAssemblyCatalog TemplateType Text 50 AllowZeroLength: FalseAttributes: Variable Length Collating Order: General ColumnHidden: FalseColumnOrder: Default ColumnWidth: 1890 Description: Polaris templatetype to use with this element DisplayControl: Text Box Ordinal Position:4 Required: False Source Field: TemplateType Source Table:ControlAssemblyCatalog Comment Memo — AllowZeroLength: True Attributes:Variable Length Collating Order: General ColumnHidden: FalseColumnOrder: Default ColumnWidth: 6012 Description: a brief comment onthe use of the control assembly-should fit into 2 or 3 lines OrdinalPosition: 5 Required: False Source Field: Comment Source Table:ControlAssemblyCatalog Explanation Memo — AllowZeroLength: FalseAttributes: Variable Length Collating Order: General ColumnHidden: FalseColumnOrder: Default ColumnWidth: Default Description: a longer commentabout properties of the assembly Ordinal Position: 6 Required: FalseSource Field: Explanation Source Table: ControlAssemblyCatalogRelationships Reference1 ControlAssemblyCatalog DCCElementsControlAssemblyCatalogID ControlAssemblyCatalogID Attributes: NotEnforced Attributes: One-To-Many Reference11 ControlAssemblyCatalogDCCActions ControlAssemblyCatalogID ControlAssemblyCatalogID Attributes:Not Enforced Attributes: One-To-Many Reference2 ControlAssemblyCatalogDCCElements ControlAssemblyCatalogID ControlAssemblyCatalogIDAttributes: Not Enforced Attributes: One-To-Many Reference6ControlAssemblyCatalog ControlAssemblyInstances ControlAssemblyCatalogIDControlAssemblyCatalogID Attributes: Not Enforced Attributes:One-To-Many Table Indexes Name Number of Fields PrimaryKey 1 Clustered:False Distinct Count: 19 Foreign: False Ignore Nulls: False Name:PrimaryKey Primary: True Required: True Unique: True Fields:ControlAssemblyCatalogID, Ascending User Permissions ACR admin ALA ALA2BJB CPI Group Permissions Admins Guests LETTERS MODIFY READ ONLY REPAIRUsers

Code Generation 240 is performed by a system which builds a SmallTalktree that is organized via a template file. The organization and logicassociated with this processing is presented in detail below in asection entitled Template Language. A template architecture facilitatesdescriptions of discrete part manufacture. Transfer Machine templatesare types that are encapsulated with data and logic associated with thetemplates. Template is not an object but a specification for transfermachine. Information organized in a tree structure.

TM1—All transfer machines will have some level of indexes. Modular listof type indexers—conveyers, transfers, shuttles, . . .

TM2—Master control panel—push buttons etc.

TM2—Transfer Machine Tree for generating according to rules ForMachines, batch (cookie)

Because of understanding of Discrete parts manufacture, a generic modelresults that allows the granularity and modularity to be architected andorganized in a structure that works well for diagnostics. Thearchitecture lends itself to adding diagnostics in a modular. Key to thediagnostics is the system provides a structured environment that lendsitself to modular diagnostics which are tied to the individualcomponents in a logical manner. This allows a designer to havediagnostics architected into the actual components.

Business Model utilizes a simulation to represent real world activitiesin a componentized fashion. Utilize a well defined interface (API) toobtain information &/or modify the real world. Export the interface asan OLE interface. They are defining the interface now. However, toutilize it today, they use Smalltalk and send strings in the OLEinterface representative of Smalltalk commands.

Instead of commands to the existing system via scripts, there will be anarchitected API to the business model. Create an object of discrete axismade up of XYZ component. Builds a tree, builds an access model andsends commands to build the code. Sending commands instead of a textstring that is interpreted. With the template library, a user can addcomponents. Sometimes the new component will need some definition to beadded on the fly.

The Causal Model Structure 250 is an expert system that relatesgenerally to discrete event control systems that control the operationof an automated machine, and more particularly to a system and methodfor developing diagnostic rules by observing the behavior of the machineand for using the diagnostic rules to detect malfunctions in thebehavior of the machine.

Discrete event control systems, such as an automated industrial controlsystem, generally control a machine having a large number of components(e.g., sensors and actuators), which may malfunction due to transienterrors and other hard or soft failures. Because of the immense number ofpossible failure points in the machine, attempts have been made toprovide control systems that automatically diagnose the malfunction andpinpoint the failure point, thus reducing costly down-time of theindustrial plant.

Known systems have approached the diagnostic problem with varyingsuccess. For example, the diagnostic engines of prior art systems oftenare based on state-machine models that can detect only certain hardfailures. Thus, transient errors and the erroneous occurrence of eventsare not diagnosed and predictions of malfunctions are not feasible.Further, such diagnostic engines often must be explicitly programmed.Or, if the engine is capable of autonomously learning the behavior of amachine, the learning session often is based on data gathered while themachine is operating in one machine state, in a fixed environmentalcondition, and at the beginning of the life of the machine. Accordingly,real-time changes in the behavior of the machine, that may be due toenvironmental conditions or the natural wear and aging process, areoften erroneously diagnosed as malfunctions. To be able to take thevarious operating conditions into account, the diagnostic engine musteither undergo a lengthy reprogramming process or be subjected to a newlearning session.

Prior art systems also generally are incapable of discerning the optimumstate-machine model to use for developing the rules to diagnose thebehavior of the machine. For example, the state-machine model willinclude a number of known sequential and temporal patterns that indicatethe proper occurrences of the various discrete events associated withthe manufacturing process. The diagnostic engine, however, mayindiscriminately develop diagnostic rules based on these patterns. Thus,a particular rule may be based on a pattern corresponding to a knowncausal relationship between events, a pattern including a sequence of alarge number of discrete events, or a pattern including a long timeinterval between discrete events. Each of these scenarios presentsdisadvantages and inefficiencies. In particular, restraining diagnosticrules to known causal relationships prevents the engine from selectingnon-intuitive timing patterns that may produce simpler, more efficientrules. Moreover, a long sequential pattern necessitates the use of alarger amount of memory to store the occurrences of the multiplediscrete events in the pattern and consumes more computing power, whilea rule based on a long temporal pattern may result in a tardy diagnosisof a machine malfunction. Further, known diagnostic engines typicallyare not capable of determining the minimum number of patterns necessaryto adequately diagnose the machine's behavior and predict malfunctionsor of judging which patterns provide the most reliable indicators of themachine's health.

Accordingly, it would be desirable to develop a versatile diagnosticengine for discrete event control systems capable of discriminatelydeveloping diagnostic rules for diagnosing the behavior of an automatedmachine. The diagnostic engine would not be restricted by known causalrelationships and, thus, could autonomously select and learn the optimumdiscrete event patterns for reliably diagnosing and predicting thebehavior of the machine. Moreover, the diagnostic engine would becapable of automatically adapting to changed operating conditions of themachine, such as environmental variations, modifications to the machine,wear and aging of the machine, and different machine states.

The present invention comprises a system and method for developingdiagnostic rules that are based on discrete event timing patterns thatoccur during operation of the machine. The system and method furtherevaluate the occurrences of the discrete events relative to thediagnostic rules to identify malfunctions in the behavior of themachine.

According to a first embodiment of the invention, a system and methodfor developing diagnostic rules for diagnosing the behavior of a machineis provided. The system and method include a plurality of controlelements which cooperate to perform at least one discrete event processand which are configured to transition between at least two differentstates. Each state transition represents a discrete event in theprocess, and the occurrence of each discrete event is communicated to amain controller. The main controller is configured to detect a timingpattern in the occurrence of the discrete events, which includes atrigger event, a result event, and a time interval between the triggerand result events. A diagnostic rule is then defined based on astatistical analysis of repetitions of the timing pattern. Thediagnostic rule is then updated in real time based on a detected changein the timing pattern.

According to one aspect of the invention, the statistical analysisincludes calculating a mean time interval between the trigger and resultevents and a standard deviation from the mean time interval. Adiagnostic rule is defined based on the statistical analysis if thetiming statistics satisfy certain defined criteria. For example, a rulemay be defined if the magnitude of the ratio of the standard deviationto the mean time interval is less than a predetermined maximummagnitude. Alternatively, the diagnostic rule may be defined if theduration of the mean time interval is less than a predetermined maximumduration.

In another aspect of the invention, a diagnostic rule may be replaceddue to a detected change in the timing pattern. For example, the mainprocessor may detect a change in which the result event follows adifferent trigger event. This change in effect creates a new timingpattern. If the standard deviation associated with the new timingpattern is smaller than the standard deviation associated with theoriginal timing pattern, the main processor will replace the originaldiagnostic rule with the new rule.

Alternatively, a machine has a first machine state for performing afirst discrete event process and a second machine state for performing asecond discrete event process. The main processor looks for a timingpattern common to at least both machine states and then defines adiagnostic rule based on the common timing pattern.

In another embodiment, a plurality of control modules are coupled to acommunication link to communicate the occurrences of the discrete eventsto a main processor. Each of the control modules is configured to detectstate transitions of at least one of the control elements. In antheraspect, a method for diagnosing the behavior of a machine configured toperform a discrete event process is disclosed. A plurality of controlelements are configured to transition between at least two states. Theoccurrence of each state transition, which represents a discrete eventin the process, is communicated to a main processor via a communicationslink. The main processor is configured to detect in real time a timingpattern in the occurrences of the discrete events, including a triggerevent, a result event, and a time interval between the trigger andresult events. A diagnostic rule is then defined based on a real-timestatistical analysis of repetitions of the timing patterns. Occurrencesof the discrete events are evaluated in real time relative to thediagnostic rule to identify whether a malfunction in the machine'sbehavior is present.

Automated control systems, such as are used in manufacturing plants, areoften used to control an industrial machine comprising a large number ofsensors and actuators which cooperate to perform a dynamic process, suchas a manufacturing or assembly process. As the automated system runs,the sensors and actuators (i.e., “control elements”) transition betweenstates in repetitive sequential, and oftentimes temporal, patterns. Forexample, in an automated system which controls a machine, such as anautomated assembly line, a proximity sensor will transition betweenstates, indicating the presence of an object (e.g., an empty bottle).Some time interval after this event, an actuator will transition betweenstates, indicating, for instance, the initiation of an operation on theobject (e.g., filling the bottle with a liquid). Next, a photodetectorsensor will transition between states, indicating that the bottle isfull. If the assembly line is functioning properly, the timingrelationships between these discrete events will be quite regular. If,however, any component of the system malfunctions, the regular timingpatterns will be disrupted. Accordingly, these regular timing patternscan provide reliable behavioral indicators useful for diagnosing themachine's health.

However, these timing patterns may vary over the life of the machinebecause of environmental factors, modifications of the machine, normalwear on the components, and other variables. Moreover, the timingpatterns may vary depending on the state of the machine. For example, inthe above-described scenario, the same assembly line may be used to fillboth large bottles and small bottles. As another example, the conveyorspeed may change from one state to the next. Accordingly, a variation inthe duration of the time interval between initiating and completing theinjection of the bottle with fluid will necessarily exist but will notbe indicative of a malfunction. The present invention provides a systemand method for diagnosing the machine's behavior which are capable ofadapting to such operational changes. In accordance with this system andmethod, diagnostic rules are discriminately defined, selected, andupdated based on the observation of the machine's discrete event timingpatterns.

Referring now to FIG. 5a, a block diagram representation of a system 510according to a preferred embodiment of the invention is illustrated.System 510 includes a main processor 512, a communication link 514, acontroller 516, and a machine 517 which comprises a plurality of controlelements 518. Control elements 18 include a plurality of sensors andactuators which cooperate to perform a dynamic, discrete eventmanufacturing process. A control program, which is stored in a memory520 of controller 516 and executed by the controller's processor (notshown), governs the manufacturing process during which control elements518 transition between states in a deterministic sequence as a result ofthe flow of materials or parts.

Each state change of a control element 518 is a discrete event that isdetected by controller 516 and stored as data in its memory 520. Forexample, in the preferred embodiment, controller 516 is a programmablelogic controller, such as a PLC-5 available from Allen-Bradley Companyof Milwaukee, Wisconsin, which is programmed to periodically scan thecontrol elements 518 to determine their respective states. Controller516 then compares the state of each element to the value of its state onthe previous scan. A state change represents the occurrence of adiscrete event, and a list of discrete events is accumulated in memory520. Controller 516 reports the discrete events to main processor 512via communication link 514, which comprises, for example, copperconductors, an RF link or other types of links suitable for conveyingdigital data.

In the preferred embodiment, main processor 512 is embodied in a generalpurpose personal computer and includes, for example, a microprocessorand a memory for storing a diagnostic engine 522 and a data file 524.Alternatively, main processor 512 may be incorporated within controller516. System 510 further includes a user interface 526 which may includea display (e.g., the personal computer's CRT or LCD display, or aperipheral display device) and a separate display memory for providingfor the output of text and graphics from main processor 512, a keyboardallowing for the entry of alphanumeric characters to processor 512, anda mouse that facilitates the manipulation of graphical icons whichappear on the display.

The user interface 526 preferably resides on a software enabled displayincluding a variety of control windows, data display windows, anddialogue boxes. For example, the control windows and dialogue boxes mayinclude icons and text which aid in configuring system 510. The datadisplay windows may be used to display the occurrences of discreteevents in a graphical format. Further, existing and active rules may bedisplayed in either in a graphical or tabular format. Malfunctions mayalso be displayed graphically or, alternatively, symbolically or as atext message in a dialogue box.

Referring still to FIG. 5a and as is well known in the art, processor512 may further include various driver and interface circuitry (notshown) to manage the flow of data on communication link 514. Forexample, the discrete event data reported from controller 516 isconveyed to data file 524 through the driver and interface circuitry.The discrete event data in file 524 may then be passed to diagnosticengine 522. The cognitive engine 522 preferably is a software programwhich can operate in either a learning mode or a diagnosing mode. Duringlearning, engine 522 is configured to analyze the discrete event data inorder to define diagnostic rules, and, during diagnosing, engine 522evaluates the behavior of machine 517 relative to the diagnostic rules.The cognitive engine 522 may define rules and evaluate behavior inreal-time or, alternatively, the discrete event data may be stored inthe memory of processor 512, or written to a data storage disk (notshown), for off-line learning of diagnostic rules or evaluation of themachine's behavior by diagnostic engine 522.

Learning Diagnostic Rules

During a learning mode, diagnostic engine 522 observes the occurrencesof the discrete events to find repetitive sequences of events whichoccur in a consistent timing pattern. Each timing pattern preferablyconsists of two discrete events (i.e., a trigger event and a resultevent) and a time interval between the two events, although diagnosticengine 522 is not prohibited from selecting timing patterns whichinclude more than two discrete events. The diagnostic engine 522 thendefines diagnostic rules based on a statistical analysis of therepetitive timing patterns, compares existing rules to newly definedrules to determine the optimum rules for evaluating the machine'sbehavior, and updates the existing rules by either updating thestatistical analysis based on further repetitions of the timing patternor replacing the existing rules with better diagnostic rules.

The various steps involved in obtaining and analyzing the discrete eventdata for rule learning are illustrated in the flow chart of FIG. 5b. Inthe preferred embodiment, as discussed above, the scan is performed bycontroller 516 (block 528). However, in alternative embodiments the scanmay be performed by other elements of system 510, such as main processor512. In any event, and regardless of whether reported in real-time orread from memory or disk during an off-line analysis, the occurrences ofdiscrete events are communicated to diagnostic engine 522, which thendetermines whether the discrete event has been previously detected(block 530) and whether the discrete event is a trigger event for anyexisting rules (block 544), is a potential or established result eventfor any rules (block 550), or is an event which has been eliminated as acandidate for a potential rule (block 552). The first time a discreteevent is detected, it is recorded as an expected event in a file storedin memory of main processor 512. The state of control elements whichnever experience a discrete event (i.e., do not transition betweenstates) are also stored in this file. During diagnosis, engine 522 mayreference this file to identify malfunctions if the occurrence of adiscrete event or a state of a control element has been detected thatwas not previously logged as an expected event.

Returning to FIG. 5b, if the detected discrete event is a trigger eventof any existing rules, then the event's time of occurrence is recorded(block 546). Otherwise, if the discrete event can be a result event forany rules (block 550), then diagnostic engine 522 determines the timinginterval between the discrete event and all possible trigger events(block 534). A statistical analysis is then performed (block 536) whichinvolves incrementally calculating a mean time interval between triggerand result events and a standard deviation about the mean time intervalas further repetitions of trigger/result timing patterns are detected.

Next, if a particular trigger/result timing pattern does not correspondto an existing rule (block 537), then the timing statistics of thepattern are evaluated to determine whether the timing pattern isadequate to define a new diagnostic rule (block 38). In the preferredembodiment, a minimum of three repetitions of the timing pattern must beobserved before the timing statistics can be evaluated to provide thebasis for a diagnostic rule, although clearly a greater number ofrepetitions would be desirable. Further, if a machine is capable ofoperating somewhat differently at some times than others (e.g., aconveyor system in which palates are randomly merged from two conveyorlines), the timing statistics will not be sufficient until diagnosticengine 522 has experienced the different operational situations.

Various criteria, or combinations of the criteria, may be used toevaluate the timing statistics. For example, a timing pattern having amean time interval or a standard deviation that is longer than the cycletime of the manufacturing process will not provide the basis for auseful diagnostic tool. Further, examining the magnitude of the standarddeviation and/or the ratio of the standard deviation to the mean timeinterval may reveal that a resulting diagnostic rule will not besufficiently precise. If the evaluation criteria are not met (e.g., themean time interval, the standard deviation, and/or their ratio are toolarge), then the timing pattern will be discarded as a candidate for adiagnostic rule (block 540), and the timing pattern's discrete eventsmay even be tagged such that they are eliminated as potential candidatesfor any rules. If, however, the criteria are met and the pattern'sresult event is not already a result event in an existing rule (block562), then a diagnostic rule will be defined using the timing statisticsof that timing pattern (block 542), thus dictating the timingrelationship between the trigger and result events.

As will be explained in more detail below, the diagnostic rulespreferably are symmetric rules. That is, the trigger and result eventseach must occur within an error band about the mean time interval of theother. The error band, which may either be fixed or selectable by auser, is a multiple of the standard deviation and, preferably, is fivetimes the standard deviation.

Once the diagnostic rules are defined, they are either retained or entera rule competition, as will be explained in detail below. If the rulesare retained, they may be updated continuously, including replacement,during the learning process based on the incremental accumulation oftiming statistics from further repetitions of the timing patterns. Asillustrated in FIG. 5b, if a timing pattern occurs that corresponds toan existing diagnostic rule (block 537), the accumulated timingstatistics for the pattern are evaluated using the criteria discussedabove (block 539). If the accumulated statistics for the rule no longermeet the evaluation criteria, then the rule may be discarded (block541). If, however, the accumulated statistics are good, then thestatistics of the rule are updated to reflect the further repetitions ofthe associated timing pattern (block 543).

The evaluation criteria applied in blocks 538 and 539 may also provide abasis for rating the merit of timing patterns and existing diagnosticrules. For example, rather than discarding an existing rule if thetiming statistics do not meet the criteria, the rule may merely bedeactivated. In such a case, the rule remains in existence and is acandidate for activation if its future accumulated timing statisticsmeet the evaluation criteria. Alternatively, if an existing rule'stiming statistics fail to satisfy the evaluation criteria by a widemargin, then the rule may not only be discarded, but also tagged as arule that should never be considered again. Likewise, if a timingpattern's statistics fail to satisfy the criteria by a wide margin, thenfuture occurrences of the pattern, or even one or all of the discreteevents associated with the pattern, may be ignored.

A detected break or inconsistency in a timing pattern also warrantsremoval of the timing pattern or the corresponding rule from furtherconsideration. For example, a timing pattern or rule may be discardedeither if its result event occurs without the prior occurrence of itscorresponding trigger event (not shown); or if the rule's trigger eventoccurs a second time without the intervening occurrence of itscorresponding result event (not shown); or if a machine state ends aftera trigger event has occurred but before its corresponding result eventoccurs (not shown). Any of these exemplary breaks in a timing patternindicates that a rule based on that timing pattern will not provide aconsistently reliable indicator of the machine's behavior.

Rule Competition

To minimize memory requirements and optimize the computing efficiency ofmain processor 512, it is preferable to select only a minimum number oftiming patterns. The selected timing patterns should also provide themost precise indicators of the machine's behavior. To achieve thesegoals, a rule competition procedure may be initiated in which anexisting rule can be updated by replacing it with a better rule. Therule competition further allows diagnostic engine 522 to selectdiagnostic rules that may not necessarily have been intuitive from aknowledge of the machine's architecture.

FIG. 5b is a flowchart setting forth the detailed logic of cognitiveanalysis in accordance with a preferred embodiment. A timing patternenters into competition with an existing rule if they both include thesame result event (block 562). The statistics of the timing pattern arecompared to the statistics of the existing rule to determine whether theexisting rule indeed provides the most accurate and efficient diagnosisof the behavior of machine 517 (block 566). If the statistics of thetiming pattern are better than the statistics of the existing rule, thenthe existing rule is updated, in effect, by discarding the existing rule(block 568) and creating a new rule based on the better timing pattern(block 542). In the preferred embodiment, the statistics which includethe smallest standard deviation are deemed to provide the basis for thebetter rule. If, however, the magnitudes of the two standard deviationsare close in value, then the mean time intervals are also compared.Although the above-described rule competition is presently preferred,diagnostic engine 522 may also be set to retain more than one rule for agiven result event and may specify other criteria, or combination ofcriteria, for the competition.

State-Dependent Learning

The selection of the best diagnostic rules may also be affected bywhether machine 517 is capable of running in more than one machinestate. For example, machine 517 may be used to manufacture severaldifferent types of parts (e.g., a standard truck cab and an extendedtruck cab), and, thus, the details of the machine's operation will besomewhat different in each state. For instance, some control elements518 may not be activated in one of the states, or, if active, the timingpatterns may be different. Maintaining separate rule bases for eachdifferent state would be prohibitive in terms of the computational andmemory requirements for main processor 512. On the other hand, defininga single set of rules that will apply to all machine states will bedifficult in most situations. Therefore, it is preferable that thediagnostic engine 522 observe the operation of machine 517 in allstates, and then define a maximum number of diagnostic rules based ontiming patterns that are common to all states and a minimum number ofrules based on timing patterns peculiar to a particular state. Further,each resulting rule is preferably tagged with code that indicates thestate or states to which the rule applies.

Before defining a common diagnostic rule, the timing statistics of thecommon timing pattern are subjected to the same evaluation process asdescribed above. If the statistics of the common timing pattern do notsatisfy the evaluation criteria (e.g., the mean time interval, thestandard deviation or their ratio are too large), however, thendiagnostic engine 522 will attempt to discover a version of the commontiming pattern that will produce an acceptable diagnostic rule. Forexample, if the time interval between the trigger and result eventsvaries between states as a result of a change in conveyor speed and ameasurement of conveyor speed is available, then a diagnostic rule canbe defined having a mean time interval that is a function of themeasured speed. As another example, if the manufacturing process candiverge into one of multiple courses of action and then resume a singlecourse, forward or backward-looking diagnostic rules can be defined thatdiagnose the final and initial events of the individual courses ofactions respectively, as will be explained below.

Symmetric and Forward and Backward-Looking Rules

In general, the diagnostic rules can be either symmetric rules,forward-looking rules, or backward-looking rules. In a symmetric rule,an event B always follows an event A and vice versa. The followingtiming pattern satisfies the requirements of a symmetric rule:

B-----A-----B

In a forward-looking rule, event A is always followed by event B, butnot vice versa. Both of the following examples of timing patternssatisfy the test for a forward-looking rule:

B-----A-----B

B-----------B

In a backward-looking rule, event B is always preceded by event A, butnot vice versa. Thus:

B-----A-----B

B--A---A----B

Preferably, the diagnostic rules are symmetric rules, and thus alsosatisfy the tests for forward and backward-looking rules. However, if asymmetric rule does not satisfy the evaluation criteria, a forward orbackward-looking rule may be defined instead, and, in the preferredembodiment, the rule includes a code indicating whether the rule is asymmetric, forward-looking, or backward-looking rule. Backward andforward-looking rules have uses other than that discussed above. Forexample, if a control element experiences bounce, the element's changeof state can still be the trigger event of a backward-looking rule.

Grouping of Control Elements

For machines having an extremely large number of control elements 518,the definition of diagnostic rules could involve extensive computationand large amounts of memory. Thus, in the preferred embodiment of theinvention, diagnostic engine 522 can employ alternative strategies thatprevent the amount of computation time and the amount of memory frombecoming excessive. For example, control elements 518 may be dividedinto independent groups which have little or no interaction with othergroups. Rules are then defined on a group basis, and the rules for eachgroup include only those discrete events which correspond to elements518 within that group.

In practice, however, groups of elements 518 usually do interact withone another, but only on a limited basis. Accordingly, some of theelements of one group can be selected to be visible to another group andare thus included in the rules for the latter group. Selecting thevisible elements may be easily accomplished based on a knowledge of thearchitecture of the control system. Further, grouping of controlelements 518 for diagnostic purposes is particularly suited for acontrol system which includes multiple distributed controllers 516. Insuch a distributed control system, each controller 516 is associatedwith a group of control elements 518, and, thus, the system architectureis easily discernible. In alternative embodiments, other strategies maybe employed, such as performing the rule definition process in stages inwhich only certain groups of control elements 18 participate at a giventime.

Diagnosis

Once diagnostic rules are learned, diagnostic engine 522 may be set tothe diagnostic mode in which incoming discrete events are evaluatedrelative to the diagnostic rules to identify existing or potentialmalfunctions in the behavior of machine 517. The evaluation of thediscrete events may be performed in several alternative manners. Forexample, referring to FIG. 5c, the timing relationship between thetrigger and result events may be evaluated relative to the timingstatistics learned during the learning process (blocks 585, 582, 588,and 590). Accordingly, if, for instance, the result event does not occurwithin five learned standard deviations of the learned mean timeinterval and the corresponding rule is either a symmetric orforward-looking rule, then system 510 will identify that a malfunctionin machine 517 has occurred (block 586).

Alternatively, and preferably, the timing statistics are incrementallyupdated in real time based on observing further repetitions of thetiming patterns associated with the diagnostic rule. For example, in thepreferred embodiment illustrated in FIG. 5c, if a scanned discrete event(block 572) is the trigger event for an active rule (block 574), a ruletimer is started (block 576). If the result event for the triggered ruleoccurs (block 578) within five standard deviations of the mean timeinterval (block 580), then the timer is stopped (block 582) and thetiming statistics are updated (blocks 588 and 584). If, however, aresult event occurs and its corresponding rule has not been triggered(block 578), or if the result event does not occur within the allottedtime interval (block 580), the system 510 identifies that a malfunctionin machine 517 has occurred (block 586).

In a preferred embodiment, both the learned timing statistics and theupdated timing statistics are retained as separate files in the memoryof main processor 512. The learned timing statistics thus provide abaseline reference for evaluating the performance of machine 517, whilethe updated timing statistics, which may be regularly replaced (e.g., ona daily, weekly or monthly basis), provide a mechanism by which thediagnostic rules can autonomously adapt in real time to changedoperating conditions. For example, in the preferred embodiment,occurrences of discrete events may be evaluated by determining whether aresult event occurs after its trigger event within a multiple of thelearned standard deviation of the updated mean time interval. Using theupdated mean time interval in conjunction with the learned standarddeviation ensures that system 510 does not interpret changes in thetiming pattern caused by manufacturing variations, such as normalmachine wear and aging, temperature or other environmental conditions,as machine malfunctions. In alternative applications, however, both theupdated mean time interval and the updated standard deviation may beused or only the updated standard deviation may be used. As yet anotheralternative, the diagnostic rules may be updated by replacing thelearned timing statistics with the updated timing statistics.

The diagnostic engine 522 preferably also tracks (block 588) the updatedtiming statistics against the learned timing statistics, although thetracking feature is optional (block 590). Accordingly, engine 522 candiagnose a large change or drift in the updated timing statisticsrelative to the learned statistics (block 592) as indicative of anexisting or potential malfunction in the behavior of machine 517 (blocks586, 596).

The criteria that engine 522 employs to identify malfunctions may varydepending on the type of diagnostic rule used. For example, symmetricand forward-looking rules can be used to identify a malfunction (a) whena result event occurs either too soon or too late after its triggerevent, (b) when a trigger event reoccurs before its corresponding resultevent has ever occurred, or (c) when a machine state ends before aresult event occurs for a rule that has been triggered. Symmetric andbackward-looking rules can be used to identify a malfunction, forexample, (a) when a trigger event occurs either too early or too laterelative to its corresponding result event, (b) when a result eventreoccurs without a corresponding reoccurrence of its trigger event, or(c) when a result event occurs during a particular machine state and itstrigger event did not precede it while in that machine state. It shouldbe understood that these types of malfunctions are offered by way ofexample only, and that one skilled in the art would recognize that othertypes of malfunctions may be readily diagnosed.

Upon detection of a malfunction, main processor 512 generates an errorsignal indicative of the malfunction and communicates it to userinterface 526. User interface 526 preferably includes a display driver(not shown) which, in response to the error signal, communicates adisplay signal to the display screen which then provides visible indiciaindicating that a malfunction has occurred. For example, alphanumericcharacters may appear on the display screen stating that a particulardiscrete event has occurred at an improper time. Or, a user may providea custom message to be displayed for a fault of a particular rule orrules. Alternatively, the display may provide a graphical representationof the faulted rule or rules which highlights the problem area, such aswith a flashing or colored marker. In other embodiments, other types ofdisplays or audio components for effectively communicating theoccurrence of the malfunction, either alone or in combination, may bereadily envisioned by those skilled in the art.

In addition to identifying timing errors, the present invention canidentify malfunctions that are characterized by the occurrence of anunexpected event. For example, after having observed machine 517 in alloperating states and conditions, diagnostic engine 522 may detect theoccurrence of a discrete event that it has never seen before or that hadnever occurred while the machine was operating in the present machinestate (i.e., the discrete event has not been recorded in the expectedevents file stored in memory of main processor 512) (block 598). Thisunexpected event may be indicative of a malfunction or of an unusualcondition, such as the opening of a safety gate. In any event,diagnostic engine 522 will generate an error signal (block 86) that istranslated into an error message that is displayed on the display screenof user interface 526.

Unexpected events also include detection of a control element which isin the wrong state. For example, in some machine states, a controlelement may never experience a discrete event and, thus, is always inone particular state. Accordingly, if engine 522 detects that thecontrol element is in or has transitioned to the other state (block598), the unexpected event will be diagnosed as a malfunction (block586).

It should also be understood that some discrete events may not be eithera trigger or a result event for any diagnostic rule (blocks 574 and578). In such a case, and provided the discrete event is not anunexpected event (block 598), diagnostic engine 522 will simply ignoreits occurrence (block 99).

Although the foregoing description has been provided for the presentlypreferred embodiment of the invention, the invention is not intended tobe limited to any particular arrangement, but is defined by the appendedclaims. For example, either the rule definition process or thediagnostic process, or both, may be performed off-line using discreteevent data that has been stored in memory. Or, the diagnostic rulesinitially may be defined by a user and then may be updated or replacedbased on real-time observation of discrete events. Alternatively, a usermay manually modify the diagnostic rules after the rules have beendefined based on real-time observation. Further, the diagnostic rulesmay be based on other variations or types of statistical analyses of therepetitions of the timing patterns.

Designer Studio

The Designer Studio is a software tool set for integrating controlsystem design, simulation, implementation and maintenance; andintegrating the control system design with external product, process andmachine (data) models. A user commences operation by opening a new orexisting project. FIG. 6 illustrates the user display for opening aproject in accordance with a preferred embodiment. All existing projectsare listed in the window 610 for a user to select from. When the userselects a project 610 it opens a Designer Studio window. FIG. 7 is aDesigner Studio window in accordance with a preferred embodiment. Thefirst panel that is created when a project is opened is the Resourcespanel 710. In this panel, a filtered hierarchical list of the projectresources is presented for further control definition. The timingdiagram panel 720 is presented for sequencing workcell operations. Italso joins the resources necessary to perform the operations at theappropriate times. The control resources window 730 provides anpredictive list of control assemblies for a user to select from based onthe resources 710 and the activities 720.

FIG. 8 is a Designer Studio display with control assemblies completed inaccordance with a preferred embodiment. A hierarchical list of thecontrol assembly types 810, control assembly instances 820, and controlassembly instance requests 830. One of the options that a user canexercise in the Designer Studio is the add operation 840 which invokedthe add control assembly logic of the add operation. This prompts theuser with an add control assembly dialog box. From the dialog box, auser can select a control assembly type and select the new button to goto the control assembly wizard FIG. 9.

FIG. 9 is a control assembly wizard in accordance with a preferredembodiment. The information in the display acclimates a user with thewizard experience.

FIG. 10 is a control assembly wizard name operation in accordance with apreferred embodiment. The user must specify a name 1000 indicative ofthe new control assembly instance that will be generated utilizing thiswizard. The user also has the option of selecting various options toinitiate other processes to create wiring diagrams, diagnostics anddocumentation for the named instance of the control assembly.

FIG. 11 is a control assembly wizard to select control resources inaccordance with a preferred embodiment. The available resources of theappropriate type are presented to the user in a window 1100. A userselects resources that will be controlled by the named control assemblyinstance from window 1100 and presented back to a user in a window 1110.Selection logic is provided which is consistent with the activity timingdiagram 720. When a particular resource is selected, all other resourcesthat conflict with that selected resource are greyed out to preventconflict selection.

FIG. 12 is a control assembly wizard to label components associated withthe control assembly in accordance with a preferred embodiment. Labelcomments 1200 are entered for each of the components at the user'sdiscretion.

FIG. 13 is a control assembly wizard summary in accordance with apreferred embodiment. When a user selects 1300 the wizard completionprocessing occurs and the control assembly is created conforming to theuser's selections.

FIG. 14 is a Designer Studio display of a new control assemblyintegration in accordance with a preferred embodiment. The new controlassembly instance 1400 is added into the Control Resources controlassembly tree utilizing the selected type and the data model of thatparticular type combined with the user selected information from thewizard and that combined information is written into the ECDB. Theselected resources that are under the control of the newly createdcontrol assembly named 1stClamps 1400 are the resources 1410 as shown inthe Control Request Chart 1420 and 1430. The prescribed order of themechanical operations for the resources 1410 refers to the time windowthat particular resources are utilized. The order of events from theprescribed order must be maintained in the Control request chart asillustrated by the placement of the Control Assembly's 1420 and 1430.Other intervening assemblies can occur, but the prescribed order isalways maintained.

A popup window that details each of the types and instances ofassemblies appears at label 1450. A Control Assembly type comprises thefollowing information. A control component which is an entity thateither sends a control signal, receives a control signal, or both sendsand receives control signals. Examples of control components include asolenoid valve (receives), proximity sensor (sends), Robot interface(both), PanelView interface (both), pushbutton (sends), indicator light(receives) or a motor controller.

Logic refers to the control and fault states, the transitions betweenstates that the control components can attain (i.e., the state space ofthe control assembly), the controller outputs which produce thetransitions, and inputs to the controller determine the current state.

For example, an n-sensor

PartPresent (input) has states such as Part Absent,

Part Present, Part out of position, Transitions

Part Absent transititioning to a Part Present state.

Part Present transititioning to a Part out of position state.

Part out of position transititioning to a Part Absent state.

Part Absent transititioning to a Part Present state.

Part Absent transitioning to a Part out of position state.

Part out of position transititioning to a Part Present state.

There are also logic for Input only types, such as:

all n off (Part Absent);

all n on (Part Present);

k of n on (k<n, k>0) (Part out of position);

There are also logic for output only types, such as: ClearToEnterLight(output) (e.g., single light also could be multiple lights); which alsohas various states such as LightOn; LightOff with Transitions, such as:LightOn transitioning to LightOff; and LightOff transitioning toLightOn.

There are also status based and causal based Diagnostics.

Status-based diagnostics—specifies the step(s) that the machine iscurrently waiting to occur (if a fault occurs it specifies the step(s)that were waiting to occur at the time of the fault, i.e., thesymptoms).

Causal model-based diagnostics—use a model of causal relationships todevelop rules that relate machine status to root causes.

For example, consider that a human mechanic has incorrectly moved themount location of a part present proximity sensor so that it is out ofalignment. Then the Status-based diagnostics would place the followingmessage in an internal diagnostic table that could be displayed:“waiting for part present sensor #2” (no automatic inference possible).

In another situation, a proximity sensor on a clamp cylinder could fail.Then, the status-based diagnostics would place the following informationinto an internal diagnostic table that could be displayed: determinesthat a machine is “waiting for clamp cylinder 2504A.”

In a causal model-based diagnostic system the logic infers that theextend proximity sensor on cylinder 2504A has failed, or that cylinder2504A is stuck and informs an operator accordingly. The causal modelutilizes a set of rules and a tree structure of information to determinethe probable root causes based on factual scenarios.

Schematic A schematic (i.e., “wiring diagram”) is a representation ofthe logical and functional connections among a set of control andmechanical components. The connections include electrical, pneumatic,and hydraulic. The preferred embodiment presents a view of each of theseconnection types and the bill of materials that make up the control andmechanical components of the control assembly type or instance.

FIG. 15 is a schematic of a pneumatic system of a control environment inaccordance with a preferred embodiment. RSWire is the applicationcreated and manufactured by the assignee. RSWire 1510 utilizes acomputer aided design engine for creating, displaying, manipulating andstoring schematics of electrical and hydraulic systems. Various viewsare all enabled withing the enterprise system in accordance with apreferred embodiment. System wide information, including detailedelectrical, pneumatic and hydraulic information, is all stored in theECDB.

Visualization

A visualization comprises entities within the control assembly that areuseful to portray textually or graphically. For example, ControlComponents can be displayed as text or a graphical representation of thecontrol component could be utilized.

Logic can be displayed as LL, function blocks or in axis-like diagrams.Diagnostics can be displayed as status messages, causal messages and asindicators on a graphic display. The information includes a threedimensional depiction of a work cell.

One way to streamline any type of programming is to provide predefinedlanguage modules which can be used repetitively each time a specificfunction is required. Because of the similar types of tools andmovements associated with different machine line stations, industrialcontrol would appear to be an ideal industry for such language modules.For example, various stations in a single machine line could employdrilling tools having identical limiting motion and configurationparameters.

In this case the idea would be to design a ladder logic language modulefor a drill once, place the drill language module into a control libraryand thereafter, each time drill logic is required, download the drilllanguage module into a control program. Similarly, language modules forother types of tools could be designed once and then used repetitivelyto reduce programming and debugging time. The module library could beexpanded until virtually all tool movements are represented. Librarycomponents would be viewed as “black boxes” with predefined interfaces,in much the same way that integrated circuits are used in theelectronics industry.

In addition, to make it easier to program in LL, a comprehensive modulelibrary would also facilitate automated LL programming using aprogramming editor. For example, an entire module library could bestored in the memory of an electronic editing apparatus. Using theapparatus, a user could designate all characteristics of a machine.Thereafter, using the designated characteristics, the apparatus couldselect language modules from the module library and assemble an LLprogram to control the machine.

The module library approach would work quite well for certainapplications like small parts material handling or simple machining. Thereason for this is that the LL logic required for these applicationstends be very small and highly reusable because the I/O count is minimaland interactions between modules are simplistic.

Unfortunately, there are many areas of industrial control for which itis particularly difficult to provide reusable language modules due torelatively large and varying job specific I/O requirements and thecomplexity and variability of interaction between modules.

One area of industrial control that defies the predefined languagemodule approach is sequential control. Sequential control is thesynchronization of individual tool movements and other subordinateprocesses to achieve a precisely defined sequence of machiningoperations. While it may be easy to enumerate all of the possiblesequences involving just a few simple tool movements, the number ofpossibilities increases rapidly as the number and complexity of the toolmovements increases, to the point where any attempt to enumerate themall is futile.

For example, a typical machine station configuration may include fivedifferent tools, each of which performs six different movements for atotal of thirty movements. In this case, each tool movement must be madedependent on the position of an associated tool. In many cases, movementof a tool must also be conditioned upon positions of all other tools atthe station. In addition, tool movements at one station are often tiedto tool movements at other stations or the completion of some portion ofa cycle at some other station. Furthermore, tool movement may also beconditioned upon the states of manual controls.

Taking into account the large number of machine line tools, toolmovements, manual control types, manual control configurations, andcross-station contingencies that are possible, the task of providing anall encompassing module library capable of synchronizing tool movementsbecomes impractical. Even if such a library could be fashioned, the taskof choosing the correct module to synchronize station tools wouldprobably be more difficult than programming required LL logic fromscratch.

For these reasons, although attempts have been made at providingcomprehensive language module libraries, none of the libraries hasproven successful at providing comprehensive logic to synchronize toolmovements. In addition, none of the libraries has made automated LLprogramming a reality. Thus, typically synchronization programming in LLis still done from scratch.

Therefore, in order to reduce programming time and associated costs, itwould be advantageous to have a more flexible means of specifyingcontrol logic for controlling machine sequences. It would beadvantageous if such a means enabled less skilled programmers to providesequential control logic. Furthermore, it would be advantageous ifreusable logic templates, comprising the basic components of asequential control program, could be composed into a library oftemplates that would be employed to produce sequential control logicwith consistent behavior and form. Moreover, it would be advantageous ifsuch a library of templates could be accessed using a programmingapparatus such as a personal computer, or the like, to further minimizeprogramming time required to program machine sequential control in LL.

In accordance with a preferred embodiment, a programming apparatus isdisclosed to construct a bar chart image or graphical depiction on acomputer screen which resembles a bar chart programming tool. A barchart is a conventional controller programming tool that consists of agraphical cycle representation illustrating all related tool movementsin a cycle. Control engineers regularly generate bar charts on paper tovisualize sequences of motion. The apparatus gleans information from thebar chart image and, using a template based programming language,constructs a template based machine model.

A template is a language module that includes some truly reusablemachine logic and a section wherein other templates can be designatedthat are required to provide machine logic for job-specific controlrequirements. When compiled, the model provides complete LL logic forcontrolling sequenced tool movements.

Thus, one object of the present invention is to provide an apparatusthat can reduce the time and cost associated with programming sequencesof tool movements in cycles. Using the inventive apparatus, a user canquickly construct a bar chart image on a computer screen that containsall of the information necessary to sequence tool movements. Theapparatus includes an editor that gleans all required information fromthe bar chart image, determines if additional templates are required toprovide job specific logic and, where additional templates are required,creates required templates and populates existing templates withreferences to the new templates. Compilation is a simple process sothat, after a bar chart image has been created, the apparatus itself cancompletely convert bar chart information into sequencing logic thusminimizing programming time and associated cost.

Another object of the present invention is to minimize the amount oftraining required before a user is competent in programming sequencinglogic. Control engineers are already familiar with the process ofconstructing and using bar charts as an aid for cycle visualization.Because the inventive apparatus interfaces with a user via a bar chartimage, control engineers should be comfortable using the presentapparatus.

Yet another object is to provide a module library that includes logicthat can be altered to accommodate job-specific requirements forsequencing cycle functions and making functions contingent upon variousfunction conditions including function states in cycle, instantaneousstates of other cycles, and instantaneous conditions of manual controldevices. The present invention includes a “bucketing” means wherebycertain conditions of related functions are placed in differentgroupings depending upon relationships between the functions and anassociated function. Control logic including an output, is provided foreach group indicating when all conditions in the group are true or whenone or more are false. The outputs are mapped into the logic moduleassociated with a function to provide synchronized automatic and manualfunction control that is conditioned as required, on the states of therelated functions. In this way, function module logic is altered toaccommodate job-specific requirements for a cycle.

IV. Template Language

In order to understand the template language concept, it is firstnecessary to understand that all machine attributes, including machinecomponents, component physical and operational characteristics, andcomponent movements, can generally be referred to as control-tasks andthat there is a natural hierarchical relationship between variouscontrol-tasks. Any machine and associated industrial process can besubdivided into a network of separate, related control-tasks that form ahierarchy of control-tasks. For example, a single machine usually hasspecific control-tasks (i.e. indexers, stations, work-units, andmovements . . . ). While the machine includes several different physicaltools or control-tasks, one of its fundamental characteristics is thatit includes a number of unique tools. There is a hierarchicalrelationship between the machine and its unique tools and every machinecan be defined in part, by a list of its unique tools.

Referring to FIG. 16, a machine tree 1611 corresponds to machine 1610 isillustrated. In FIG. 16, direct connection between two elementssignifies a parent/child relationship between two elements where thehigher control-task in the tree is the parent and the lower control-taskis the child. Where a parent/child relationship exists, the childcontrol-task represents one fundamental characteristic of the parentcontrol-task. In FIG. 16, the hierarchical relationship between themachine 1610 and the indexer 1620 is illustrated at the top portion ofthe machine tree 1611.

The most fundamental characteristic of indexer 1620 is that it includesfive stations 1630-1635 and therefore, stations 1630-1635 can behierarchically related to the indexer as illustrated. Each work-unit ishierarchically related to its associated station and one or more axesare hierarchically related to each work-unit.

In addition to the hierarchical relationship identified above, eachmachine tree 1611 component can also have a direct relationship to anaxis. For example, all of the indexer 1620, stations and work-units inmachine 1610 may require a pneumatic air source for operation. Where amachine-wide air requirement exists, the machine 1610, as opposed to oneof its child components, should control an air valve to provide air toall machine components. Thus, in addition to its list of indexers, otherfundamental characteristics of a machine as a whole are axes that aredirectly connected to the machine 1610. In FIG. 16, in addition to beingdirectly connected to its indexer 1620, the machine 1610 is alsoconnected to an air axis 1686 for opening an air valve.

Similarly, the indexer 1620 is connected to a transfer axis 1688 forcontrolling the transfer bar for all stations 1630-1635. Moreover, eachof the stations 1631-1634 that includes a clamp is connected to adifferent clamp axis for controlling an associated clamp.

A third fundamental defining aspect of each tree component is whether ornot the component requires a control panel. In the present example, themachine 1610 includes a main control panel 1658 for controlling theentire machine and therefore, a control panel 1658 is shown on themachine tree 1611 directly connected to the machine 1610. In addition,the horizontal mill 1622 includes a local control panel 1657 forcontrolling only the mill 1622. A control panel 1657 is shown directlyattached to the horizontal mill in tree 1611.

Therefore, the entire industrial process shown can be viewed as amachine tree 1611 made up of the hierarchically-related components orcontrol-tasks shown in FIG. 16. Each control-task can be entirelydescribed by identifying its most fundamental characteristics, includingcontrol-tasks from the next hierarchical level, any directly-connectedaxis control-tasks and any directly-connected, control panelcontrol-tasks. With this understanding of an industrial machine,template language can now be explained.

The template language guides a user to assemble from a set ofprogramming units called modules a complete and correct machine tree1611. Individual modules are identified with templates, which includetruly reusable control logic so that, when a template-based machine treeis compiled, a complete control program for an industrial process isproduced.

A template is a model program unit available for repeated use as apattern for many modules based thereon. A template can be analogized toa data entry form wherein form identification can refer to either ablank instance of a master copy or a completed instance. In thisdescription, the term “template” is used to mean the essence of apattern as well as a completed instance of the pattern referred to alsoby the term “module”.

The template language includes two types of language statements. A firststatement type includes statements that are wholly independent of theunderlying control language form. A second statement type includesunderlying control language form itself, plus extensions to that form,making the form more flexible. Typically, the underlying language formwill be completed in ladder logic. The second statement type isparticularly useful where automated electronic editors are used tocompile a template based machine tree, thus generating a control programin the underlying control language form. Each statement type will beexplained separately. Statements Independent of the Underlying ControlLanguage Form Referring again to FIG. 16, a typical set of templatesused to provide a program for machine 1610 have a template typecorresponding to each machine tree control-task type. For example, atemplate set for machine 1610 would include machine, indexer, station,workunit, axis and control panel templates. In addition, the set wouldinclude other more detailed templates to further define each of theaforementioned templates. A template is a model program unit availablefor repeated use as a pattern for many modules based thereon.

Referring to FIG. 17, a typical template includes a template typedesignation and may include a name field which must be filled each timea template is used so that the specific instance of the template can bedifferentiated from other modules, including other instances of the sametemplate.

In addition, each template 1794 may include LL logic sections 1795having one or more rungs of LL logic. The idea here is that for eachspecific template type 1794 used to represent a specific control-tasktype in a machine tree 1611, there will often be some logic, albeit inmany cases minimal, that is always required for the specificcontrol-task type. For example, for safety purposes, a master controlpanel will always include ON-OFF means for turning the machine on andoff. Thus, every machine template will require ON-OFF LL logic and an LLlogic section 1795 will provide the universally required logic.

Each template 1794 may also include child module specification sections1796. The contents of the child module specification section 1796represents one type of language statement that is wholly separate fromthe underlying control language form. In the child ID section 1796, thetemplate provides an area where a user can define module specificationsthat designate other modules required to further define the designatingmodule.

The relationship between a designating module and a designated module isa parent/child relationship wherein the designating module is the parentand the designated module is the child. For example, a machine modulefor machine tree 1611 would include a module specification designatingan indexer module 1620. Similarly, in the present example, the machinemodule would include two separate module specifications to separatelyspecify a “master control panel” module and an axis module named “air”which further detail the main control panel 1658 and the air axis 1686,respectively. The “master control panel”, “air” and “T1” modules wouldall be child modules of the parent machine module.

Continuing, the indexer 1620 module would include a child modulespecification designating five separate station modules, one for each ofthe five stations, 1630-1635, as well as a module specificationdesignating an axis module named “transfer” to control the transfer bar1620.

The fourth station module 1634 would include a first modulespecification to a workunit module named “horizontal mill” and a secondmodule specification to specify an axis module named “clamp”. The clampmodule would detail logic for controlling clamp 1644 by either includingcomplete LL logic or designating other modules that would complete LLlogic for clamp control.

The work unit module named “horizontal mill” would specify axis modulesnamed “spindle”, “main slide” and “cross slide” as well as a controlpanel module to define control panel 1657. Similarly, each of the otherstation and work-unit modules would specify other modules until everycontrol-task in the entire industrial process has been completelydefined and reflected in a template-based tree, mirroring machine tree1611.

Referring to FIG. 1800, the machine tree 1811 expands even further, eachaxis comprising a number of different control-tasks and correspondingmodules. In FIG. 1800, only the main slide axis 1802 associated with thehorizontal mill 1822 is shown. However, it should be understood thattree branches, like branch 1800 in FIG. 18, must be provided for eachaxis and each control panel. While the control panel branches willinclude modules based on templates that are different than the templatesrequired to specify an axis, the process of populating modules withrequired lists to define parent modules is the same. FIG. 18 will beexplained in detail below.

Moving down the machine tree, modules associated with lower treecontrol-tasks generally include an increasingly larger relative sectionof control logic. At the extreme, the final modules at the distal lowerends of the tree consist entirely of control logic and have no childspecification sections. Surprisingly, only a few dozen templates arerequired to provide modules that completely describe an industrialprocess. When compiled, so that LL logic sections in child modules areplugged into their designating parent modules, a complete LL logicprogram can be provided.

The preferred template language includes different kinds of modulespecifications that can be used to accommodate different circumstances.For example, one type of module specification is a module “list” whichallows zero or more component modules of a specific type (i.e.associated with a specific template). Referring again to FIG. 1600, anindexer module may include a module list called “station” which includesspecifications to five modules, one for each of the five machinestations 1630-1635. In this way, a single module specification canreference five station modules. Each station module in the list must beassigned a unique job specific name to ensure that it can be differentfrom other modules designated in a common list specification. In theexample here, the stations and, hence station modules, are referred toas 1630-1635.

Yet another kind of module specification is an “optional” modulespecification which results in either no instances or exactly oneinstance of the designated type. For example, a preferred indexertemplate includes an optional module specification for an indexercontrol panel. While it is not necessary to have an indexer controlpanel, where a machine line is unusually long, it is often advantageousto include an indexer control panel somewhere along the line to allowlocal indexer control. The optional module specification gives aprogrammer the option, based on job specific requirements (i.e. thelength of a machine line), to provide LL logic for an indexer controlpanel when one is desired. In the present example, the indexer does notinclude a control panel and, therefore, no module would be created.

Another module specification kind is a “renameable” module specificationwhich results in a single named component module of a designated type,but will also allow a job-specific name to override the default name.Another kind of module specification is a “fixed” specification. Here,the template designated by the specification does not result in a childmodule. When compiled, fixed templates simply expand into thedesignating modules. Fixed specifications are not named.

Another kind of module specification is a “named” module specificationwhich results in a single, named component module of the type identifiedin the specification. For example, for safety purposes, all machinesrequire a master control panel. Thus, a preferred machine templateincludes a named module specification called “master control panel”which identifies a single instance of a master control panel template.

One final kind of module specification is a “choice” specification whichmakes a selection from a list of mutually exclusive module types basedon job specific information. For example, while a control panel requiressome type of interactive device for a user to turn a machine on or off,a user may prefer either a push button or a selector switch. To thisend, in a control panel template, a choice specification is providedwhich includes two fixed module specifications, one for a push buttonand another for a selector switch. Like a fixed module specification,the template associated with a chosen type is simply expanded when themachine tree is compiled (i.e. no module results from a choicespecification).

A second type of language statement wholly separate from the standard LLrung form includes data definitions. Data definitions are common inprogramming language and should be familiar to a person of ordinaryskill in the art. Therefore, data definitions will not be explained herein detail. Suffice it to say however, that in template language, datadefinitions are required to declare and reserve space for all PLC datatable types such as inputs, outputs, timers, counters, etc., and allowsthe association of attributes with each declaration.

Extensions to the Underlying Control Language Form (LL)

While some logic is always the same for a specific machine treecontrol-task type, other logic is job-specific and distinct to anassociated given module and would be extremely difficult to furnish inprewritten LL or other template sections. For example, one typicalprerequisite for turning on a machine 1610 to begin an industrialprocess is that all local control panels (i.e. control panels other thanthe master control panel) be in remote mode often called “automatic”.Remote mode means that a control panel forfeits control over the localmachine section to an operator panel located higher up in the machinetree, for instance the master control panel. Local mode (e.g. “manual”),disables the parent operator panel and permits only local control of asection of the machine. Thus, one LL logic rung called “all child nodesremote” in a main control panel module should include a series ofcontacts, one contact for each local control panel. Each local controlpanel module would include a coil corresponding to its contact in the“all child nodes remote” rung. When the local control panel is in remotemode, the local panel module coil would be energized, thus closing thecorresponding contact in the “all child nodes remote” rung. Thus, a coilat the end of the “all child nodes remote” rung would indicate when alllocal panels are in automatic or remote mode allowing the machine 1610to be turned on.

Prior to designing a machine there is no way of knowing how many localcontrol panels will be required. One machine may not require any localcontrol panels while another machine may require ten or more localcontrol panels. The number of local control panels required for amachine is job-specific. This means that prior to designing a machine1610, there is no way to determine the number of contacts required inthe “all child nodes remote” rung in a main control panel module.Unfortunately, standard LL rung forms do not allow for variable numbersof contacts and, therefore, cannot adjust to job-specific requirements.While a programmer could alter the form of an “all child nodes remote”rung while manually programming using templates, when the programmer isusing automated editors there is presently no easy way to change rungform to accommodate job-specific parameters.

To overcome this limitation, the template language includes both macroinstructions and a symbolic expression language that are extensions tothe standard LL rung form itself. One macro instruction is an “AND list”instruction which provides a mechanism by which variable numbers ofseries contacts can be provided in an LL rung. The number of contactscan be tied to job specific requirements. For example, where four localcontrol panels are required in an “all child nodes remote” rung, the“AND list” macro would provide four contacts, one for each local panel.In the alternative, where ten local panels are provided the “AND list”macro would provide ten contacts, one for each local panel.

The symbolic expression language is used with the macro instructions todesignate macro operands. The symbolic expressions include singlecharacters that may be concatenated with template-authored symbolicnames (defined using Data Definition statements) to form reusableoperand specifiers. These symbolic expressions may be used by placingthem above LL instructions in an LL rung. A preferred set of symbolsconsists of three path specifiers and two separators.

Path specifiers indicate where relevant operand definitions can befound. Separators allow concatenation of more path information such asthe name of a specific child module, data item, or attribute. A firstpath specifier is the symbol “$”. Specifier “$” indicates the name ofthe module that the specifier appears in. For example, if specifier “$”appeared in the master control panel module, the specifier would providea path to the master control panel module. In addition, the specifierwould also provide partial paths to all main control panel childmodules.

A second path specifier is symbol “#”. Symbol “#” indicates the instanceof a particular member of a list. A third path specifier is symbol“{circumflex over ( )}” which may be followed by a template type name.Symbol “{circumflex over ( )}” represents the first ancestor (i.e.parent, grandparent . . . ) module whose type matches the typedesignated after the symbol.

A first separator is symbol “.”. Symbol “.” indicates that the textfollowing is the symbolic name of a child module or data definitionwithin the program unit designated by the path specifier preceding theseparator. A second separator is symbol “ indicating that the textfollowing it is the symbolic name of an attribute associated with theentity designated by the path specifier preceding the separator. For thepurposes of this explanation, attributes will include module list names.

Referring to FIG. 19, a standard “all child nodes remote” LL rung 1925that might appear in master control panel logic is illustrated. The rung1925 includes three contacts MACHINE.LP1.AUTO, MACHIINE.LP2.AUTO andMACHINE.LP3.AUTO and a single coil named MACHINE.ALL CHILD NODES REMOTE.Each of the three contacts “MACHINE.LP1.AUTO”, MACHINE.LP2,AUTO”, and“MACHINE.LP3.AUTO” corresponds to a separate local control panel (notshown).

Referring also to FIG. 20, the symbolic expression language describedabove can be combined with an “AND list” macro to provide an LL rung2027 that can expand into rung 1925 having three contacts when compiled.An AND list macro 2028 and a single “all child nodes remote” coil makeup rung 2027. The “AND list” macro 2028 includes symbol “$” whichspecifies a path to the present module. The “indicates that the symbolicname “LPS” that follows is an attribute associated with the presentmodule. In this case “LPS” is a module list associated with the maincontrol panel module. Thus, the expression “$” represents a module listin the main control panel module. The module list provides operands tothe “AND list” macro. The “AND list” macro 2028 includes the condition“Auto” with the path specifier “#”. Specifier “#” indicates that the“Auto” condition should be concatenated with the operands above the “ANDlist” command.

When compiled by an automated compiler (or by hand), the “AND list”macro 2028 expands into series contacts, one contact for each referencein the module list “LPS.” For example, assuming the module list “LPS”included a job-specific membership of three instances name “LPI,” “LP2”and “LP3,” rung 2027 would expand into rung 1925. Similarly, if themodule list “LPS” included a job-specific membership of ten instances,rung 2027 would expand into a rung having ten series contacts, eachcontact named for a different one of the ten instances in the list.Thus, using the symbolic expression language in conjunction with the“AND list” macro, the number of series contacts can vary, depending uponjob-specific parameters.

A second macro instruction is an “OR list” instruction. The “OR list”,like the “AND list”, when combined with the symbolic expressionlanguage, provides for variable rung forms, depending upon job-specificparameters. However, instead of providing series contacts, the “OR list”macro provides variable numbers of parallel contacts. An exemplary rung2130 including an OR list macro 2131 is illustrated in FIG. 21.“$Requests” specifies a module list named “Coil Requests” having ajob-specific membership. Each instance in the “Coil Requests” list is tobe concatenated with a coil request name and all instances are to beplaced in parallel in rung 2130 when the rung 2130 is compiled.Therefore, if module list “Coil Requests” includes three job-specificinstances, three parallel contacts (one contact named for each instance)will replace the “OR list” macro 2131 when compiled. If the module list“Coil Requests” includes ten job-specific instances, the “OR list” macro2131 would be replaced by ten, uniquely named parallel contacts.

The “OR” and “AND list” macros are extremely powerful and add a level offlexibility to programming in the template language that cannot beprovided using the standard LL rung form. Using the macros inconjunction with the symbolic expression language facilitates templatesthat refer to variable job-specific parameters and to data items definedin other modules by associated templates even before the job specificparameters and data items are defined.

In addition to the macros and symbolic expression language, there is oneother type of extension to the standard LL rung form itself calledpseudoinstructions. Pseudoinstructions take three forms: XPC, XPO andOTX which correspond to standard XIC (examine if closed), XIO (examineif open) and OTE (output enable) LL instructions. XPC and XPO stand forexamine predicate closed and examine predicate open, respectively. OTXstands for output expansion.

One of the problems with any LL programming shortcut based on a modularlibrary of LL logic components is that logic must be provided toaccommodate all possible requirements. Therefore, in many cases logicthat is not required in a specific application will be provided to covergeneral requirements. Moreover, sometimes logic required in generalapplications are not permitted in specific applications.

For example, typically there is less danger associated with movements ina cycle's second half than with movements in the first half andtherefore, a reduced set of conditions may be provided for secondhalf-cycle movements than for first half-cycle movements. The firsthalf-cycle includes movements that shift the mill spindle toward or intoa workpiece. The second half-cycle includes movements that shift thespindle out of and away from the workpiece. Prior to any axis movementthere is typically a set of conditions that must be met to ensure a safemove. Therefore, a reduced set of conditions can apply to secondhalf-cycle movements, the reduced set reflecting the reduced possibilityof danger.

The preferred template set includes only one template type correspondingto axis movement. Therefore, the axis movement template must includelogic for both the full set of conditions used in the case of a firsthalf-cycle movement and the reduced set of conditions used in the caseof a second half-cycle movement. Referring to FIG. 22, a required fullset of conditions will show up in an LL logic rung 2234 as a full set2233 of series-connected contacts C1-C5. When all of the conditions aremet, all of the contacts C1-C5 are closed and an associated output coilOUT is energized, indicating that an associated axis movement can begin.

The reduced set of conditions corresponding to the second half-cycleshows up in LL logic as a branch 2235 parallel to the full set 2233 ofcontacts, the branch including a reduced set of contacts C6, C7; onecontact for each condition in the reduced condition set. Thus, the axismovement template provides LL logic 2233, 2235 for movements in both thefirst and second half-cycles. While both the full and reduced logic setsmay be applicable to movement in the second half-cycle, they are notboth applicable to movements in the first half-cycle. In other words, ifan axis movement module corresponds to a first half-cycle movement,branch 2235 including the reduced logic set is not permitted, but branch2235 is required for a second half-cycle movement.

XPC and XPO pseudoinstructions are used to examine compile timeconstants representing configuration options such as the ones shown inFIG. 22. The effect of the evaluation will be either a short or an opencircuit in the generated program, depending on evaluation result. Forinstance, the result of an XPC on a true condition is a short circuitwhile the result of an XPO on a true condition is an open circuit. InFIG. 22, an XPC contact 2236 identifying a second half-function isprovided in series with the logic of branch 2235. The XPC contact 2236shorts when rung 2234 is associated with a second half-cycle movementand is an open circuit when rung 2234 is associated with a firsthalf-cycle movement. Therefore, upon compiling, the XPC contact 2236leaves branch 2235 in rung 2234 when a corresponding movement is in asecond half-cycle and removes branch 2235 when a corresponding movementis in the first half-cycle.

A side effect of the compile time evaluation of pseudoinstructions canbe further optimization of the generated logic. For instance, an opencircuit in series with other input instructions renders the otherinstructions unnecessary. A branch that is shorted renders parallelbranches unnecessary. With the XPO and XPC instructions, unnecessaryinstructions can be removed from their associated circuits withoutchanging the meaning of the circuit. Upon compilation, optimization canripple recursively through a program, potentially causing entire rungs,including coils, to be discarded.

Template language allows expression and encapsulation of that, and onlythat, which is universally true of a particular machine component oroperating characteristic. A side effect of this is that the granularityof some of the templates can be very fine. This means that the topologyof some of the circuits after expansion can be very inefficient. Forexample, referring to FIG. 22, the redundant branch 2233 includingcontacts C1-C5 would be produced for second half functions. To rectifythis, the OTX pseudoinstruction enables the template author to instructthe compiler to optimize certain circuits. When the compiler encountersan XIC or XIO instruction whose contact is an OTX coil, it will replacethe instruction with an in-line expansion of the actual contents of therung associated with the OTX coil.

For example, referring to FIG. 22-1, a first LL rung 2220 includescontacts A and B and an OTX coil C. A second LL rung 2222 includescontacts C and D and other “stuff” where contact C corresponds to theOTX coil C. When compiled, coils A and B corresponding to OTX coil C areexpanded into the coil in branch 2222 yielding branch 2224 as shown inFIG. 22-2. This provides the template author with a large degree ofcontrol over the resulting topology of the generated circuits.

Referring now to FIGS. 23-35 an exemplary set of templates is providedwhich can be used to better understand template language generally. Thepreferred template group is a subset of a template set specificallydesigned for the metal-removal industry. Referring to FIG. 23, a machinetemplate 2398 includes the template type designation “machine” and ablank name field 2399 that has to be filled in to identify a specificmachine module. The machine template 2398 itself does not directlyinclude LL logic and hence, has no LL logic section. Instead, themachine template has a child module specification section 2396 aincluding several module specifications including a named modulespecification called “master control panel” 2300 and both axis- andindexer-list module specifications 2302, 2304, respectively. Becauseeach machine must include at least one control panel for safetypurposes, every machine template (and hence every machine module) mustinclude a master control panel specification 2300.

Referring to FIG. 24, a master control panel template 2406 includes anLL logic section 2494 b required for start and stop push buttons. Thelogic in section 2494 b is universally required for all master controlpanels. In addition, the master control panel template 2406 includes achild module specification section 2496 b that references other modulesusing module specifications. The modules designated in the child modulespecification section 2496 b may be required to completely provide LLlogic to control the master control panel 2458. Whether or not modulesmust be designated in the child ID section 2496 b depends on jobspecific requirements. Note that named module specification “remotecycle enabler” and fixed module specification “operator panel” arerequired attributes of any master control panel module.

Referring again to FIG. 23, the module list named “axis” 2302 includes alist of all machine-wide axes. In the present example, the “air” axis isthe only machine-wide axis and therefore, the axis-module listspecification would include only a single specification called “air”.Referring to FIG. 25, an axis template 2508 includes an axis templatedesignation, a name field 2510, and a child module specification section2596 c having three separate module specifications for switch packet,trajectory and actuator, all of which have to be detailed to completelydefine an axis.

Referring again to FIG. 23, the indexer module list specification 2304includes a list of indexer modules, one for each machine indexer. In thepresent example, there is only a single indexer T1 and, therefore, onlyone indexer entry, identifying indexer module T1, would appear in theindexer list specification. Referring to FIG. 26, an indexer moduleincludes an indexer template designation, name field 2614, and a childmodule specification section 2696 d. The module ID section 2696 dincludes an optional module specification 2616 for a control panel andtwo module list specifications, one for axis 2618 and another forstation 2620. In the present example, because there is no indexercontrol panel, the optional control panel would not be designated.Because we have one indexer axis (i.e. “transfer”), there would be onespecification in the axis module list specification 2618 named“transfer”. In addition, because there are five stations, there would befive specifications in the station module list specification 2620. Eachstation designated in module list 2620 would identify a differentstation module corresponding to a different one of the five stationsS15.

Referring now to FIG. 27, the station template 2722 is nearly identicalto the indexer template 2712 of FIG. 27, except that, instead of havinga station module list specification, the station template 2722 includesa work-unit module list specification 2724. In the present example,there would be five separate station modules like the one in FIG. 27,each module identified by a different name in the name field 2725 andcorresponding to a like-named station in the station module list 2720 ofthe indexer module named “T1”.

Referring now to FIG. 28, a work-unit template 2826 includes a work-unitdesignation, a name field 2828, and a child module specification section2896 e having only two module specifications, an optional operator panelmodule specification 2830, and an axis module list specification 2832identifying all axes associated with a work-unit. In the presentexample, because the horizontal mill 2822 includes three axes (spindle,main slide, and cross slide), three separate specifications would beincluded in the axis module list specification 2832 identifying threeseparate and distinctly named axis templates. In addition, because thehorizontal mill 2822 includes a local control panel 2857, the optionaloperator panel module specification would be designated.

The templates in FIGS. 37-43, represent all of the templates required tocompletely specify an axis. To specify an axis, it is necessary todefine all positions associated with an axis and switches that indicatepositions. The switches act as controller inputs for the axis. Inaddition, it is necessary to define possible axis-movement requests,herein referred to as trajectories. Moreover, it is also necessary todefine actuators used to effect trajectories and how a controller willcommunicate with the actuators (i.e. coils and coil requests). Coils andcoil requests act as controller outputs to the actuators.

Referring also to FIG. 18, a template-based tree branch 1800 for oneaxis, the main slide axis of the horizontal mill, is illustrated showingthe hierarchical relationship between modules required to define themain slide axis. Referring also to FIG. 25, to accommodate all theinformation required to specify an axis, the axis template 2508 includesa child ID section 2596 c having a named “switch package” modulespecification 2591 a and sections 2591 b and 2591 c for trajectory andactuator module list specifications, respectively. Therefore, in modulelist specification 2591 b, the trajectory list would only include twospecifications, one for “advance” and one for “return”. In FIG. 18, the“advance” and “return” trajectories are shown as child modules 1804 and1806.

Referring still to FIG. 25, the main slide subassembly includes only asingle motor, which is the main slide actuator. Therefore, only oneactuator “motor” will be designated in the actuator module listspecification 2591 c. In FIG. 18, the main slide actuator is shown aschild module 1808. Switch package module 1810 is also a child module ofmain slide axis module 1802. Referring also to FIG. 37, the switchpackage template 3793 includes child ID section 3796 f having two modulelist specifications 3794 and 3795. A “limit switch” module listspecification 3794 is used to specify axis switches. The main slide axisincludes advanced switch 3739 and returned switch. Thus, switch modulelist specification 3794 would specify two switches as switch packagechild modules named “advanced LS” and “returned LS.” The two switchesdefine three main slide positions named “advanced,” “intermediate” and“returned.” Therefore, position module list specification 3795 wouldspecify three positions as switch package child modules named“advanced,” “intermediate,” and “returned.” Referring to FIGS. 37 and38, a position template 3803 is used to provide a position module foreach position designated in position list section 3795. Each positiontemplate 3802 includes a name field 3801 for identifying the specificposition modules (i.e. in the present case “advanced”, “intermediate”and “returned”). In addition, each position template 3803 includes fourseparate module list specifications 3804 a, 3804 b, 3804 c and 3804 dcorresponding to two possible types of limit switches and two possiblestates of each type of switch (i.e., normally open (NO) tripped, NOreleased, normally closed (NC) tripped, and NC released).

Each of the lists 3804 a, 3804 b, 3804 c and 3804 d is populated withswitches from switch module list specification 3894 that are in acorresponding state (i.e., tripped or released). For example, when amain slide subassembly is in the advanced position, the advanced switchis tripped and the returned switch is released. Assuming both switchesare wired normally open (NO), the advanced switch would be listed in theNO tripped LS module list specification 3804 a while the returned switchwould be listed in the NO released LS module list specification 3804 b(in this case no switches would be listed in module list specifications3804 c and 3804 d). Referring again to FIG. 18, the NO tripped advancedswitch and NO released returned switch are shown as child modules 1816and 1817 for the position module 1813 named “advanced.” Similarly,position templates for the “intermediate” and “returned” positions wouldbe populated with appropriate switches. In FIG. 18 intermediate positionmodule 1814 has two child modules, “NO released advanced LS” 1818 and“NO released returned LS” 1819 while returned position module 1815 haschild modules “NO released advanced LS” 1820 and “NO tripped returnedLS” 1821.

Referring to FIGS. 25 and 39, a trajectory template would have to bedesignated and populated for each axis trajectory (i.e., each movementrequest). For the horizontal mill main slide, there are twotrajectories, “advance” and “return”. Therefore, there would be twotrajectory modules, one named “advance” and a second named “return”which are shown as child modules 1804 and 1806, respectively, in FIG.18.

Each trajectory can be divided into various moves. A simple single speedlinear trajectory includes three moves. An “initial” move beginstrajectory motion followed by an “intermediate” move between twopositions, the trajectory ending with a “final” move that stops themotion. Thus, referring still to FIG. 39, the trajectory template 3909includes a child module specification section 3996 g for a move modulelist specification. Referring also to FIG. 18, the “advance” trajectorymodule 1804 includes “initial” 1822, “intermediate” 1823 and “final”1824 move child modules. The “return” trajectory 1806 includes similarchild modules 1825, 1826, 1827.

Referring to FIG. 40, a move module based on move template 4016 must beprovided for each move in child module specification section 4096 h.Each move template 4016 includes a child module specification section4096 h for a coil request module list specification. A coil request is arequest to a specific coil to actuate an actuator (e.g. motor) when aspecific position associated with a move has been reached. For example,on a two speed motor, one coil may drive the motor at one speed tofacilitate one move. A second sequential move, however, may requireexcitement of two coils to activate two motors to achieve a greaterspeed once an intermediate position has been reached. Thus, a singlemove may require two or more different coil requests. A coil requestmodule based on the coil request template shown in FIG. 41 must beprovided for each coil request designated in the child modulespecification section 4096 h of a move module.

Referring to FIGS. 25 and 42, for each actuator designated in actuatormodule list specification 2591 c, an actuator module based on actuatortemplate 4218 must be provided. Each actuator module must be named todistinguish specific modules. The actuator template 4218 includes achild module specification section 4296 i for designating a coil modulelist specification 4219. A coil is an output to drive a motor or thelike. Referring also to FIG. 18, for the horizontal mill main slidethere are only two coils, a “work” coil and a “home” coil shown as childmodules 1828 and 1829. Referring to FIG. 43, a coil module based on coiltemplate 1821 must be provided for each coil module designated in aspecification 1819.

Once all the trajectories, actuator, limit switches, positions, moves,coil requests, and coils have been identified and associated module listspecifications have been populated and required modules have beenprovided, the tree branch and corresponding LL logic required tocompletely control the axis has been designated. Modules based on all ofthe templates illustrated in FIGS. 37-43 are required to define eachaxis.

C. Function Contingencies

Using a complete template set it should be fairly easy for one skilledin the art to construct a complete template-based machine tree using thetemplate set. However, at least one template-based programming aspect isnot entirely intuitive based upon a perusal of the complete templateset. This complex template programming aspect is how the functiontemplate 4936 in FIGS. 49A and 49B which controls function performanceis to be used.

Function performance must be limited by the instantaneouscharacteristics of other functions in the same cycle. Theseinstantaneous characteristics can be gleaned from a bar chart. For thepurposes of referring to various functions in this explanation, whereone function is observed from the perspective of another function, thefunction observed will be referred to as an observed function and theother function will be referred to as the observing function.

Four separate relationships exist between any two of the four functions,(or, more precisely, between the action of the observing function andthe done condition of the observed function). A first relationship is a“stable/unstable” relationship. Stable simply means that an observedfunction does not start or stop during an observing function. A secondrelationship is a “cancel by other/cancel by me” relationship. Where anobserved function is unstable from the perspective of an observingfunction, the state of the observed function is changed either by theobserving function or by some other condition. When the observingfunction changes the observed function state, the observed function issaid to be canceled by the observing function. From the perspective ofthe observing function, the second function is categorized as “canceledby me”. When some condition other than the observing function changesthe observed function state, from the observing function perspective,the observed function is “canceled by other”.

A third relationship is a “my half-cycle/other half” relationship. “Myhalf-cycle” means that an observed function starts before an observingfunction in the observing function's half of a cycle. “Other half” meansthat the observed function is either in the opposite half-cycle as theobserving function or, if both observing and observed functions are inthe same half-cycle, the observed function starts after the observingfunction.

The fourth relationship is a “position/latch” relationship. Thisrelationship deals with the nature of the observed function itself. Afunction can have one of three different natures, position, latch or acombination of both. Functions of the position nature will end when aspecific axis position is reached.

Referring now to FIG. 50, an attributes table 5031 is illustrated thatincludes an attributes column 5032, twelve “bucket” columns A-L, and alist of the possible function attributes described above. A user canemploy this table 431 to categorize, from the perspective of anobserving function, all other observed functions in a cycle into one ofthe twelve buckets A-L. For example when function B1 is the observingfunction, observed function B2 is a stable, other half, positionfunction which places function B2 in bucket J. Similarly, with functionB1 observing, observed functions B3 and B4 would be placed in bucket J.

With function B2 observing, observed function B1 is a stable, my half ofcycle, position function which places function B1 in bucket I. Withfunction B2 observing, both observed functions B3 and B4 go in bucket J.With function B3 observing observed functions B1 and B2 are stable,other half, position functions placed in bucket J while observedfunction B4 is an unstable, canceled by me, other half, positionfunction placed in bucket F. With function B4 observing, functions B1and B2 go in bucket J while function B3 is a stable, my half-cycle,position function in bucket I. Note that with function B4 observing,function B3 is considered “stable” because the cutter clear positionCCP, once achieved, is not reversed until after function B4 has beencompleted.

For every function B1-B4, there is an inverse function in an oppositehalf-cycle that is stable and is a position. For example, function B3 isthe inverse of function B1 while function B2 is the inverse of functionB4. Thus, all cycle functions can be divided into two groups, a firstgroup being the inverse of the other. Gathering information about bothfunction groups requires duplicative effort. Therefore, when defining afunction by its relationships with other cycle functions, only afunction corresponding to the first group, or, in the alternative, thesecond group, is required. When bucketing functions with function BIobserving, a user would work backwards through the cycle bucketingfunctions until a duplicative function is encountered. Working back, asexplained above, observed function B4 would be placed in bucket J.Observed function B3, however, is the inverse of function B1 andtherefore represents duplicative information. Here, because function B3is the inverse of function B1, B3 could not possibly be performed duringB1 and therefore, B3 need not be bucketed. As for function B2information, that information is reflected in the bucketing of functionB4 and is not needed.

Thus, for each function in a cycle, only one other function would bebucketed (i.e. B4 bucketed for B1, B3 for B4, B2 for B1, and B1 for B2).Obviously, the present example is extremely simple. However, one ofordinary skill in the art should easily be able to apply these teachingsto bucket functions for complex cycles.

In addition to instantaneous characteristics of other functions in thesame cycle, commencement and continuance of a function is alsocontingent upon three other conditions. A first condition is that afunction will not start in an automatic sequencing mode of operationunless it is in its start position. A second contingency is that afunction will not start in a manual discrete stepping mode of operationuntil all required control buttons have been triggered by a user. Athird contingency is that a function will not start in any operatingmode unless prescribed safety requirements are met.

Referring again to FIG. 50, the attributes column 5032 includesattributes “my start position”, “push button”, and “safety”corresponding to each of the three contingencies identified above. Threeadditional bucket columns M-O are provided, each column corresponding toa different one of the three conditions. Each instance of a condition isbucketed into an appropriate column, M-O.

Referring to FIGS. 49A and 50, after all functions and contingenciesthat must be bucketed have been bucketed according to attributes table5031, they can be used to populate lists in a module list specificationsection 2342. The list specification section 2342 includes one modulelist specification for each bucket A-O in table 5031. Each module listshould be populated with functions or other contingencies correspondingto the list name.

Referring to FIG. 49A, the function template 2336 also includes aplurality of “AND list” macros 234A-234O, one macro corresponding toeach module list specification in section 2342. When expanded, each “ANDlist” macro 2344A-234O expands into a series-connected set of contacts,one contact for each member in an associated module list specification.The coils in series with the macro are excited only when each contact inthe series is true. Thus, coil “A” will not be excited unless allfunctions bucketed and placed in the “unstable, canceled by other, myhalf, position” module list specification 2348 are true. Similarly, coil“O” will not be excited unless all safeties in safety module listspecification 2346 are true.

In addition to the instantaneous characteristics of other functions inthe same cycle and the other contingencies identified above, functionperformance may also depend on the physical characteristics of an axis.Physical characteristics of an axis or an industrial process can putadditional constraints on the manner in which a function can safely beperformed. Functions can be divided into three types based on the kindsof constraints placed on them.

A first function type is a normal function. Normal functions can beperformed either in forward or reverse directions without damaging aworkpiece or an associated machine's components. Performing a functionin reverse means making the axis move in the opposite direction of thetrajectory related to the function. This may produce the same effect as,but in terms of function logic is not the same as, performing thefunctions inverse function.

A second function type is a non-reversible function meaning that, afterthe function has been performed in whole or in part, in the forwarddirection, it cannot be reversed and performed in the other direction.An example of a non-reversible function is a transfer bar forwardmovement function which cannot be reversed once it has started forwardas it might cause damage to work pieces or a fixture's axis components.

The third function type is a non-repeatable function. A non-repeatablefunction cannot be started forward a second time once it has beenperformed to completion. For example, where an axis device places a pinin a hole while performing a function, after the function is performed,the function cannot again be performed because the hole is alreadyblocked by the first pin. Hence, the function is non-repeatable.

To accommodate the three separate function types (i.e. normal,non-reversible and non-repeating), template 2336 includes a choicemodule specification 438 having “normal function mapping” 2339,“non-reversible function mapping” 440 and “non-repeatable functionmapping” 2341 specifications. Depending upon function types, a userwould choose one of said specifications 2339-2341 and provide anassociated mapping module.

The only other function characteristic that must be determined tocompletely define the function template 2336 is to specify in whichhalf-cycle a function occurs, first or second. Cycle half specificationis required for contact 2350 in FIG. 49B.

After all of the module specifications have been designated for thefunction template 49A, 49B, the user is done programming control of thespecific function. Referring to FIGS. 49A and 51 when normal functionmapping is chosen in template 5136, the bucketed functions andconditions from table 5031 are mapped into mapping coils 5149 accordingto a normal function mapping template 5151. Similarly, where thenon-reversible or non-repeating mapping choices are made in template2336, other mapping templates are used to map bucketed functions andconditions slightly differently. Thus, using a template set, functionperformance can be made contingent upon axis physical characteristics,instantaneous characteristics of functions sharing a cycle, the state ofa cycle itself, the state of any control means associated with thefunction, and whether or not job-specific safeties associated with afunction have been met.

D. Editors

In addition to providing truly reusable subsets of control logic, atemplate set makes automated programming possible wherein programmingeditors mirror the diagraming conventions which are already widely usedin industrial control programming.

The editors allow a user to construct images that are similar toconventional diagrams and documentation. During image construction, theeditors use information from the images to create modules and populatespecifications in existing modules. After a user has used the editors todescribe all aspects of a machine, all required modules have beenpopulated and a complete template-based machine tree is formed in editormemory. Then, a computer is used to compile the machine tree and providerequired LL control logic. Referring to FIG. 29, the four editors arereferred to herein as a machine editor 2962 a, an axis editor 2962 b, acontrol panel editor 2962 c, and a bar chart editor 2962 d.

In addition to imitating traditional diagrams, each of the editors hasbeen designed to incorporate conventional computer interface featuresthat most programmers should already be comfortable using. Conventionalfeatures include an interactive computer terminal that presentsprogramming options in pull down menu form and allows option selectionusing a mouse or other similar selection means.

1. Machine Editor

The machine editor 2962 a allows a user to build a floor plan imagedirectly on a computer monitor. During image construction, the machineeditor 2962 a constructs a template-based machine tree reflecting thefloor plan image. In addition, while a user is constructing atemplate-based tree, the editor 2962 a is simultaneously gleaninginformation from the tree and either creating new template-based modulesor populating existing modules so as to provide a template-based treespecification.

The machine editor 2962 a only facilitates construction of the floorplan and the portion of a machine tree corresponding thereto. Themachine editor 2962 a cannot specify specific aspects of an axis, anoperator panel, or a sequence of events. Specification of these moredetailed aspects of a machine are reserved for the axis 2962 b, controlpanel 2962 c, and bar chart 2962 d editors, respectively. As depicted inFIG. 29, the machine editor 2962 a accesses the other special editorswhen specific detail is required.

Referring now to FIG. 30, an initial machine editor image 3042 that isdisplayed on a monitor at the beginning of a programming sessionincludes a menu bar 3044 at the top of the image 3042 and a split screenhaving a tree section 3049 and a floor plan section 3050. The treesection 3049 provides an area wherein the editor 2962 a visuallydisplays a template machine tree as a corresponding floor plan isconstructed. The floor plan section 3050 is where the floor plan itselfis constructed.

The menu bar 3044 includes two choices, FILE and EDIT. The FILE choiceallows a user to store, retrieve, and delete files from memory. The FILEchoice operates in a manner that should be familiar to an artisan ofordinary skill in the art and therefore will not be explained here indetail. The EDIT choice allows a user to simultaneously construct andedit both a floor plan in the floor plan section 3050 and atemplate-based tree in the tree section 3049.

Initially, a single icon 3052 corresponding to a main control panelappears in the upper left-hand corner of the floor plan section 3050 andboth a machine module reference and a master control panel referenceappear in the upper left-hand corner of the tree section 3049. Themaster control panel reference is below the machine module reference andindented to show a hierarchical parent-child relationship. These initialentries are provided to a user because they are always required asdesignated in the templates. Every template-based tree must begin with amachine module and every machine must have a master control panel forsafety purposes. The machine module reference corresponds to the entirefloor plan as constructed in the floor plan section 3050. The mastercontrol panel module corresponds to the control panel icon 3052.

Furthermore, to uniquely identify the machine, the editor 2962 ainitially provides a floating name box 3054 prompting the user to entera machine name. The machine name is used by the editor 2962 a toidentify the correct machine module for a given industrial process. Inthe example above, the process is named “AB1” and therefore, the machinemodule name is AB1 and AB1 is eventually placed at the top of the treerepresentation in tree section 3049 (see FIG. 31).

After entering the machine name, a user can start building a floor planby selecting the EDIT choice from menu bar 3044. When EDIT is selected,the editor 2962 a provides a menu of possible programming options forfurther detailing whatever item in the floor plan section 3050 isselected. At the beginning of a programming session, there are only twopossible items that can be selected, the machine itself or the mastercontrol panel. To select the master control panel, the user would clickon the master control panel icon 3052. To select the machine, the userwould click on an area of the floor plan section 3050 that does notinclude an icon. Typically, a user would wait until near the end of aprogramming session to detail the master control panel because he wouldknow more about the machine at that time.

Referring now to FIG. 31, with the machine selected for editing and theEDIT choice chosen, a pull-down menu 3156 appears providing options forediting the machine module AB1. Referring also to FIG. 23, a machinetemplate 2398 can only be edited by adding to or subtracting from theaxis 2302 or indexer 2304 module list specification. Therefore, thepull-down menu 3156 includes the only four possible machine moduleoptions: ADD INDEXER, ADD AXIS, DELETE INDEXER, and DELETE AXIS. (Deleteoptions are only provided after an axis or indexer has already beenadded.) Referring also to FIG. 16, in the present example, because themachine requires a single directly-connected axis, the user would selectADD AXIS from the menu 3156. Because each axis requires a unique name,after selecting ADD AXIS, the editor 2962 a would request a name for thenew axis using a floating name box (not shown).

In the present case, a user would enter “air” as the name of the axis.Then, the editor 2962 a would provide an axis module reference named“air” below the AB1 module reference in the tree section 3149 and wouldalso provide an air axis icon 3158 a next to the master control panelicon 3152 in the floor plan section 3150. The “air” module reference,like the master control panel reference, will be indented from the AB1module reference to show a parent/child relationship.

While the editor 2962 a is forming the floor plan in floor plan section3150, the editor 2962 a is also creating modules and populating existingmodule specifications. Referring to FIG. 32, the method 3243 of creatingand populating begins at process block 3245 where the editor 2962 agleans new image information from the image. Where an “air” axis imagehas been added to the floor plan and named, the editor 2962 a wouldidentify a new axis designated “air”.

At decision block 3246 the editor 2962 a determines if the newinformation requires an additional module. Where an additional module isrequired, at block 3247 the editor 2962 a creates an additional module.Here, after the “air” axis has been named, the editor 2962 a creates anaxis module named “air”. Next, at decision block 3248, the editor 2962 adetermines if the newly-gleaned information is required to populate anexisting module. If so, at block 3251 the editor 2962 a populates theexisting module.

After the required modules have been created and existing modulespopulated, at block 3253 the editor 2962 a determines if the image insection 3250 is complete. Typically image completion will be signaledwhen a user stores an image via the FILE option in menu bar 3144. Whenthe image is complete, the editor 2962 a exits process 3243. If theimage is not complete, the editor 2962 a cycles back to process block3145 and continues to glean new image information used to createadditional modules and populate existing modules.

After the “air” axis has been added to the floor plan and named, theuser again selects EDIT from the menu bar 3144, this time selecting theADD INDEXER choice to add an indexer T1. When ADD INDEXER is selected,because each indexer module requires a unique name, the editor 2962 awould request an indexer name using another floating name box.

After entering “T1” to identify the indexer in the present example, theeditor 2962 a would provide a “T1” module reference below and indentedfrom the AB1 module reference in the tree section 3149 and would alsoprovide an indexer icon 3160 in the floor plan section 3150. Using themouse the programmer could click on the indexer icon 3160 and drag itinto a desired position suitable for building the desired floor plan. InFIG. 31, the indexer icon 3160 is shown in the right hand portion of thefloor plan section 3150. Referring again to FIG. 32, each time newinformation is added to the floor plan image, the editor 2962 a followsprocess 3243 to create new modules and populate existing ones.

If needed, a user can again select EDIT and add additional indexers andaxes to provide a template-based machine tree and floor plan thatcorresponds to any machine configuration. For example, if a machinerequires a source of pressurized coolant in addition to the air source,a coolant axis could be added to the machine module by again selectingADD AXIS in the EDIT menu. In the present example, however, the machineincludes only one axis (“air”), one indexer (“T1”) and the requiredmaster control panel. Thus, at this point, fundamental characteristics(i.e. axis, indexers, and control panel) of the machine module have beenidentified.

Next, the user can further specify either the indexer “T1” or the “air”axis. To further specify the indexer TI, the user selects the indexericon 3160 with the mouse and then again selects EDIT. Referring again toFIG. 26, the indexer template 2612 can be edited only by adding anoperator panel, a station or an axis specification, or by deleting astation or axis specification. Therefore, referring to FIG. 33, in thiscase, the EDIT menu would provide five options: ADD STATION, ADD AXIS,ADD OPERATOR PANEL, DELETE STATION, and DELETE AXIS (delete options areonly provided after station or axis has been added). At the indexerlevel an operator panel is optional and should only be provided whenrequired to meet job specific characteristics.

As with the machine module, here, where an axis is to be added to theindexer T1, the user would select ADD AXIS and name the axis. The editor2962 a would then provide an axis module reference below the indexermodule reference T1 and indented in the tree section 3149 and provide anaxis icon in the floor plan section 3150. In the present example, theindexer T1 includes a “transfer” axis shown below the indexer “T1”reference in section 3149 and shown as transfer icon 3158 b in section3150 of FIG. 33. The transfer icon 3158 b initially appears near the topof the floor plan section 3150 and is dragged down next to the indexericon 3160 to signify the relationship therebetween.

To add a station to the indexer, the user selects ADD STATION and namesthe specific station. The editor 2962 a then provides a station modulereference in the tree section 3149 and a station icon in the floor plansection 3150 which can be dragged into its proper location next to theindexer icon 3160. Additional stations are selected in the same mannerbut must be provided different names.

In the present example, because there are five separate stations, theuser adds five separate stations to the floor plan, each of which isindividually represented in both the tree 3149 and floor plan 3150sections. In FIG. 33, all five stations, named S1-S5, are shown as fiveseparate icons 3366, 3367, 3368, 3369 and 3370. The icons have beenpositioned to show machine component relationships.

This process of selecting and naming menu items to construct both thetemplate-based machine tree and the floor plan continues until the floorplan is completely designated, from the machine level down to the axislevel. A complete floor plan for the process is shown in FIG. 34including icons representing the indexer, five stations, a work-unitnamed “LH” at the first station corresponding to a loader, a work-unitnamed “LV” at the second station corresponding to a drill, an LV unit atthe third station corresponding to a turret drill, an LV unit at thefourth station corresponding to a horizontal mill, an “RH” at the fifthstation corresponding to an unloader, an operator panel represented byicon 3400, a master control panel represented by icon 3452, and aseparate icon for each axis.

In the tree section 3149, LH stands for “left horizontal” meaning thework-unit is positioned on the left hand side of its associated stationand moves horizontally with respect to the station. Similarly, LV standsfor “left vertical” meaning movement is along a vertical axis and RHstands for “right horizontal” meaning the work-unit is positioned on theright hand side of its associated station and moves horizontally withrespect to the station. Despite the drill, turret drill, and horizontalmill all having the name LV, each is distinguishable because of theirparent/child associations with different parent stations. Importantly,the parent/child associations are recognized by the compiler.

As in FIG. 16, the loader at station S1 in FIG. 34 includes a singleaxis named “shuttle” 3458 c. Similarly, the drill at station S2 includestwo axes named “spindle” 3458 d and “slide” 3458 e, and the turret drillat station S3 includes axes named “spindle”, “slide” and “turret” (iconsnot shown). The mill includes axes named “spindle” 3458 f, “main slide”3458 g and “cross slide” 3458 h, and the unloader includes an axis named“ejector” 3458 i.

When the floor plan is completed, the portion of the template-basedmachine tree in tree section 3149 is completely designated. Next, thespecial editors can be used to define the characteristics of each axis3458 a-3458 i and the control panels, as well as define sequences ofaxis movement.

Referring to FIG. 34, the horizontal mill is represented in the floorplan image as the fourth station S4 and all other components connectedthereto. Thus, station S4 includes a left vertical mill LV having alocal control panel represented by icon 3400 and spindle, main slide andcross slide axis represented by axis icons 3458 f, 3458 g, 3458 h.

2. Axis Editor

Referring again to FIG. 34, when an axis icon is selected, the machineeditor 2962 a switches editing control to the axis editor 2962 b whichallows a programmer to specify axis characteristics. Referring again toFIG. 29, the axis editor 2962 b, like the machine editor 2962 a, followsthe same process for gleaning new image information to create newmodules and populate existing modules. The only difference is that theaxis editor 2962 b and machine editor 2962 a glean required informationfrom different images and create and populate different module types.

FIG. 35 depicts a control diagram 3574 for the main slide linear axis,as displayed on a programming monitor, along with additional informationrequired to derive data for a template compiler. A flow chart of theprocess by which the user creates the control diagram is depicted inFIG. 36. Initially at process step 3572, the user constructs a behaviorprofile 3570 that is similar to the control metaphor for the desiredmachine cycle. The behavior profile 3570 is illustrated in the upperright portion of the display in FIG. 35 between lines 3575 and 3576representing the extremes of the linear motion. The remainder of thedisplay designates “physical attributes” of the axis, which attributesconstitute the input and output signals required to operate the machineaccording to the behavior profile.

At the outset of defining the operation of the main slide axis, a blankbehavior profile is displayed with only the outer lines 3575 and 3576that correspond to the extremes of the linear movement of the main slidesubassembly. An EDIT choice appears at the top of the profile in a menubar which, when selected, provides a menu of items that can be used todefine the axis. In particular, the menu will include switches,actuators, and work requests. A box 3573 in which the user enters thelength of the machine stroke, i.e. the distance between positions D0 andD1 also appears. In the present example, the stroke distance is 16.0inches and can be entered in the box 3573 by selecting the box 3573 andentering an appropriate stroke via a keyboard.

n FIG. 36 the user uses the edit menu to select a menu item on theterminal screen to define one of the limit switches, for example aswitch for the fully returned position of the subassembly. After thatselection, a limit symbol is displayed on a monitor and box 3577 appearsto the left of the symbol within which the user enters the switch name,such as “returned LS”. A schematic representation 3580 of the limitswitch appears adjacent to its symbol to indicate whether the limitswitch contacts close or open when struck, or tripped, by a subassemblydog. A dog symbol 3582 also appears on a horizontal line 3578 whichrepresents the linear axis of movement. One end of the dog symbol 3582initially abuts the LEFT vertical line 3575 and another vertical line3584 appears at the other end of the dog symbol.

The graphical representation of the limit switch indicates when thelimit switch is sending an active input signal to a programmablecontroller with respect to the positions of travel by the main slidesubassembly. At step 3585, the user indicates whether the switch isnormally opened or closed. This is accomplished by using a mouse or thekeys on a keyboard to place the cursor over the schematic symbol 3580and press the button to toggle the symbol open or closed. In a similarmanner at step 3587, the user “grabs” the dog symbol 3582 to positionthe symbol along line 3578 to indicate positions on the axis where thedog trips the limit switch. The length of the dog symbol 3582 can bechanged by using the cursor to grab one end of the symbol and stretch orcontract the dog symbol. As the position and length of the dog symbolchanges, so does the position of the vertical line 3584 which indicatesthe location along the linear axis at which the dog engages anddisengages the corresponding limit switch. The dog symbol 3588 for theadvanced limit switch also is created on the control diagram in thismanner by the user again selecting the limit switch menu item at step3590. Defining the other limit switch (i.e. “advanced LS”) also createsan additional vertical line 3586 on the control diagram 3566.

The definition of the two limit switches divides the stroke length intothree segments referred to as positions 3592, 3593, and 3594. Thelocation and length of the dog symbols 3582, 3588 designate in which ofthese positions 3592-3594 the corresponding limit switch will be trippedby a carriage dog. In the present example, the returned limit switch istripped by the dog when the subassembly is stopped in the “returned”position 3592. The advanced limit switch is tripped by the dog only whenthe subassembly is at the “advanced” position 3594. When neither theadvanced nor returned LSs are tripped, the subassembly is in an“intermediate” position. As the limit switches are employed to signalwhen subassembly motion should be stopped, the operational positions3592-3594 relate to different sections of the control metaphor.Specifically, “returned” position 3592 corresponds to the stoppedposition at distance D0 and position 3593 corresponds to the subassemblymoving between distances D0 and D1. Similarly, position 3594 correspondsto the fully advanced position when the subassembly is stopped atdistance D1. The terms “position” and “operational position,” as usedherein, refer to physical locations at which the machine has differentoperating characteristics, for example movement speed and direction. Aposition may be a single physical location or a region of physicallocations, such as the region between distance D0 and D1.

After defining the signals for the two limit switches, the user thenspecifies the number of actuators (motors) which are employed to drivethe subassembly. A separate block 3596 is created each time the userselects an ADD ACTUATOR menu item from the program editor software atstep 3590. This enables the user to specify the number of motors, inthis case one for the main slide motor. Each block 3596 is subdividedinto three boxes for actuator name, speed (IN/MIN) and direction. Theblocks 3596 may be subdivided further depending upon the types ofactuators, i.e. . . . single speed-single direction, single speed-twodirection, two speed-single direction, or two speed-two directionmotors. In the present example, the main slide motor is a single-speed,two-direction device and thus its block 3596 has a single-speed box 3597and two-direction boxes “work” 3599 a and “home” 3599 b. At step 3600,the user enters the speed of the slide motor in box 3597 but does notdesignate direction since both the advancing and retracting motions areprovided by this actuator type. The editor software loops through steps3600-3602 until information has been provided for each actuatorselected.

Each time an actuator block 3596 is added, removed or edited, thegraphical editor has a column for every direction and/or speed coil forthe motors and a line which corresponds to all of the possiblecombinations of motor speeds going toward and away from the workpiece.The exemplary main slide motor can advance the subassembly toward aworkpiece at 100 inches per minute. Similarly, the motor can be used toretract the subassembly from a workpiece at 100 inches per minute. Ablack dot in various matrix locations indicates which of the motors areenergized and their direction to produce the speed listed in the rightcolumn of the matrix 3604.

When the matrix 3604 is formed, separate horizontal bars 3606 and 3608are created across the behavior profile 3570 above and below the zerospeed axis 3610. Each of the horizontal bars 3606 and 3608 is formed byindividual segments within each of the operational positions 3592-3594.At step 3604, the user grabs the segments of the horizontal bars 3606and 3608 in the behavior profile 3570 and positions the segmentsvertically to indicate the advancing and returning speed at which thesubassembly is to move within each of the positions 3592-3594. Forexample, when an advance request is received, the subassembly is to movefrom the returned position 3592 through the intermediate position 3593at a speed of 100 inches per minute. Upon the subassembly reaching theadvanced position 3594 at distance D1, the speed goes to zero bystopping the motor. Thus, the portion of the behavior profile 3570 abovethe zero speed axis 3510 corresponds to moving the subassembly toward aworkpiece. A similar representation in FIG. 35 is given for the speed ofthe subassembly away from the workpiece by locating the segments ofhorizontal bar 3608.

Referring still to FIGS. 35 and 36, the user then provides the names ofseparate request signals that indicate when the subassembly is toadvance toward the workpiece and when it is to return. These names areplaced into boxes 3512 and 3514 as request signals to be used by thelinear axis editor as described below. In the example these requestsignals have been named simply “advance” and “return”.

Next, the user is afforded an opportunity at step 3607 to definecomposite position signals, which are signals energized when an axis iswithin a specified region defined using a subset of operationalpositions 3592-3594. A composite position definition label box CCP 3521is added to section 3516 of diagram 3574 each time a user selects an ADDCOMPOSITE POSITION menu item. For each composite position added a usermust enter a name in the label box CCP′ and must select one or moreoperational positions by clicking the mouse-controlled cursor in thevicinity of the intersection of an imaginary horizontal line, extendingfrom the center of the label box CCP′, and one of the operating positionregions 3592, 3593 or 3594, each selection recorded by the axis editoras a graphical arrow 3518, 3519. In the example, a composite positionnamed “cutter clear” 3517 is defined to be energized whenever the mainslide subassembly is in either the “returned” or “intermediate”position.

As the user creates the control diagram 3574 of FIG. 35, the axis editor2962 b converts icons and images from the diagram 3574 into modulespecifications required to define an associated axis module. Referringagain to FIG. 25, to completely define both physical and operatingcharacteristics of an axis the editor 2962 b must glean information fromthe axis diagram 3574 to populate the module specification named “switchpackage” 2591 a and two module list specifications named “trajectory”2591 b and “actuator” 2591 c.

Referring to FIGS. 25, 32 and 35, to define the axis module 2508 so asto correspond to control diagram 3574, while a user is constructing thediagram 3574, the editor 2962 b identifies all limit switches,positions, composite positions, actuators, trajectories, and moves fromthe diagram 3574, one at a time, at block 3545.

Each time a user designates a limit switch, request, actuator, positionor composite position, the editor 2962 b identifies the designation andpopulates an appropriate module or creates a new module. In the mainslide control diagram of FIG. 35, the editor 2962 b would identify boththe returned limit switch 3538′ and advanced limit switch 3539′, boththe main slide advance 3512 and return 3514 requests, the main slidemotor actuator 3596, the main slide positions including “returned”,“intermediate”, and “advanced” 3592, 3593 and 3594 respectively, thecomposite position “cutter clear” CCP′ and various moves correspondingto both the return 3514 and advance 3512 trajectories. The advancetrajectory 3512 would include an “initial” move corresponding toposition 3592, an “intermediate” move corresponding to position 3593 anda “final” move, which slows the subassembly to zero speed, correspondingto position 3594.

At block 2251, after each of the axis designations, the editor 2962 bpopulates corresponding lists, placing limit switches in the limitswitch module list specification 3794, positions in the position modulelist specification 3795, trajectories in the trajectory module listspecification 2591 b, actuators in the actuator module listspecification 2591 c, composite positions in the composite positionmodule list specification 2591 d and moves in the associated move modulelists 2596 g in FIG. 25. In addition, for each list entry, the editor2962 b creates a new module at block 147. For example, referring toFIGS. 35 and 37, for the main slide control diagram 3574 the limitswitch module list specification 3794 in FIG. 37 would include modulereferences named “returned LS” 3538 and “advanced LS” 3539 while thepositions list 3795 would include module references named “returned”3592, “intermediate” 3593 and “advanced” 3594. Referring to FIGS. 35 and25, the trajectory module list 2591 b would include module referencesnamed “advance” and “return” corresponding to requests 3512 and 3514respectively and the actuator module list specification 2591 c wouldinclude a single module reference named “motor” of the type actuatorcorresponding to designation 3596. Referring to FIG. 39, the module listspecification named “move” for the module of type trajectory named“advance” would include references to “initial,” “intermediate” and“final” moves and the list named “move” for the module of typetrajectory named “return” would also include references to “initial,”“intermediate” and “final” moves. Each list entry would correspond to adifferent module.

Referring to FIG. 38 the position template 3803 includes four separatelists 3804 a, 3804 b, 3804 c and 3804 d corresponding to the twopossible types of limit switches and the two possible states of eachtype of switch (i.e. normally open (NO) tripped, NO released, normallyclosed (NC) tripped, and NC released.) Referring also to FIG. 35, theeditor 2962 b correlates positions 3592, 3593 and 3594 with tripped anduntripped switches and switch type (i.e. NO or NC) to populate each ofthe module list specifications 3804 a-3804 b of FIG. 38 with switches inconditions that correspond to a position.

For example, referring again to FIG. 35, when the subassembly is in thereturned position the “returned LS” 3538 is tripped and the “advancedLS” 3539 is released. Assuming both the returned 3538 and advanced 3539switches are normally open (NO), the returned position 3592 wouldinclude one normally open and tripped returned LS 3538 and one normallyopen and released advanced LS 3539. Recognizing this, the editor 2962 bwould populate the NO tripped LS module list specification 3804 a withthe returned LS 3538 and would populate the NO released LS module listspecification 3804 b with the advanced LS 3539. The other two listspecifications 3804 c and 3804 d in the position template 3803 would beleft empty.

Referring to FIGS. 35 and 38, axis editor 2962 b creates a compositeposition module based on template 3803 a for each composite position insection 3516 of diagram 3574. The editor provides each module a name3801 corresponding to the name in label box CCP′ and provides a“selected positions” module list specification 3804 e corresponding tothe names of the selected operational positions 3518 and 3519. Thesingle rung in template 3803 a generates a simple logic circuit thatenergizes a signal whose name corresponds to module name 3801 a wheneverany one of the positions in the selected positions module listspecification 3804 e is energized.

Referring to FIGS. 25 and 39 the editor 2962 b creates a trajectorymodule based on trajectory template 3909 for every trajectory referencedin the trajectory module list specification 2591 b.

The second rung 3913 determines if the trajectory associated with thespecific module is at its start position. This is done by using an ORlist macro as explained above. The OR list macro and associated logic3915 determines if any other trajectories are done. Where any othertrajectory is done, it is assumed that the present trajectory is at itsstart position. The third rung 3914 simply checks if the trajectoryassociated with the module is completed and is used by other trajectorymodules to determine if they are at their start positions. The start anddone status of each trajectory is used by the bar chart editor 2962 d asdescribed in more detail below.

Referring now to FIG. 40, a move module based on move template 4016 isprovided by the editor 2962 b for each potential move designated in atrajectory module. Each move template 4016 includes a unique module listnamed “coil request”. The editor provides a coil request module based onthe coil request template shown in FIG. 41 for each coil requestreferenced in a move module 4016.

Referring to FIG. 42 the editor 2962 b creates an actuator module basedon actuator template 4218 for each actuator module referenced in theaxis template 108. Each actuator module 4218 includes a module list 4219called coil wherever a list of uniquely named coils are provided for theactuator associated with the parent actuator template 4218.

Because the axis editor gleans information from diagram 3574 while auser is constructing the diagram and simultaneously constructs theportion of the template-based machine tree corresponding to the axisbeing designated, by the time diagram 3574 is completed, all of theinformation required to provide LL logic to specify the axis iscomplete. This process must be repeated for each axis on the floor plan3150.

3. Control Panel and Bar Chart Editors

Referring again to FIG. 34, at this point the only icons on the floorplan image that have not been completely defined are the main controlpanel 3452 and horizontal mill control panel 3400. In addition, whileall of the separate axes for each machine element have been designatedat this point, none of the axis movements have been linked together.

To specify a control panel, a user must designate mode selection, manualcontrol, and indicator devices. In addition, for each manual controldevice and each indicator device, the user must designate both the cycleand the specific function in the cycle to which the device relates. Tothis end, with reference to FIG. 29, although the control panel 2962 cand bar chart 2962 d editors are separate, they must be used together.Initially, the control panel editor 2962 c is used to identify modes ofoperation, mode selector switches corresponding to the modes ofoperation, and various cycles that are controllable via the controlpanel. Then, the bar chart editor 2962 d is used to define the differentfunctions and their temporal relationships that make up each cycle thatis controllable via the control panel. Finally, after the cycles arecompletely defined, the control panel editor 2962 c is again used toidentify manual control devices, including lights, buttons and switches,that correspond to desired functions in the defined cycles.

To define the horizontal mill control panel, a user selects icon 3400 inFIG. 34. When icon 3400 is selected, editing control passes in FIG. 29from the machine editor 2962 a to the control panel editor 2962 c.Referring yet again to FIG. 32, the control panel 2962 c and bar chart2962 d editors, like editors 2962 a and 2962 b, follow process 3243 inFIG. 32 to glean information from screen images to create new modulesand populate existing modules during image construction. There is oneexception to this general rule and that is that the bar chart editormust also perform a bucketing step using the attributes table 5031 ofFIG. 50 after a cycle has been defined to populate function lists in themodule list specification sections of associated function modules. Thiswill be described below.

Referring now to FIG. 44, the initial display for a preferred controlpanel editor 2962 c includes a menu bar 4422, a name field 4424, andthree specification fields: MODE CONTROLS, CYCLES, and MANUAL CONTROLSreferred to by numerals 4425-4427, respectively. The menu bar 4422includes five options, a conventional FILE option and MODES, CYCLES,CONTROLS and LIGHTS options that can be used to add or delete modes ofoperation, cycles, specific controls, or lights respectively.

Because all control panels have at least local and remote modes ofoperation, the control panel editor 2962 c initially designates a singlethree-pole selector switch represented in the MODE CONTROLS field 4425by icon 4430 which can be used to choose either a remote mode (AUTO),local mode (MAN), or an off state (OFF). If desired, a user can use theMODES option in menu bar 4422 to pull down a mode menu for creatingother modes (tool change or service modes). If a third mode isdesignated via the modes menu, the icon 4430 is automatically altered toshow a four-pole selector switch in the MODE CONTROLS field 4425.

Other than icon 4430, initially there are no other designations infields 4425, 4426 and 4427. Because manual controls have to be relatedto some cycle function, prior to designating manual controls, machinecycles have to be defined. To this end, a user can choose the CYCLESoption from menu bar 4422 to pull down a cycles menu to designaterequired cycles. When a single cycle is added, the editor 2962 c promptsthe user to name the cycle. When a cycle is added, an icon including auser-assigned name is placed in the CYCLES field 4426. In the presentexample, the horizontal mill control panel includes only two cycles, amill cycle including movements of the main slide and cross slidesubassemblies, and a spindle cycle for turning on and off spindle.Therefore, two cycle icons 4432 and 4434 corresponding to mill andspindle cycles are referenced in field 4426.

To define each cycle, the user separately selects each of the cycleicons 4432, 4434 to enter the bar chart editor 2962 d two differenttimes. Referring to FIG. 45, a bar chart image 4536 that would beconstructed for the mill cycle using the bar chart editor 2962 d isdepicted. It should be readily apparent that the bar chart image 4536constructed using the bar chart editor 2962 d is very similar to aconventional chart. The similarity between a conventional bar chart andimage 4536 is meant to make it easy for a user trained in the use ofconventional diagrams to use the bar chart editor 2962 d.

When a user enters the bar chart editor 2962 d, the initial image onlyincludes basic required bar chart designations. Required designationsinclude the cycle time box 4538, first sequence 4540, second sequence4541 and whole cycle 4542 icons, interlocking yield 4544 and stop 4545symbols corresponding to icons 4540, 4541 and 4542 and REQUESTS 4546LABELS 4547 and LATCH 4548 headings.

The editor 2962 d also provides a menu bar (not shown) including aREQUESTS option which allows a user to add or delete requests from thebar chart and a LABELS option allowing a user to label specificlocations in the bar chart. To construct the bar chart image 4536, auser selects an ADD REQUESTS option from a pull down request menu.Thereafter, the editor 2962 d provides a complete listing of everypossible request associated with the horizontal mill. For example,possible requests for the horizontal mill would include: cross slideadvance, cross slide return, main slide advance, main slide return,spindle run, and spindle not run. In addition, other possible requestswould include whole cycle, reset, first sequence, and second sequencerequests to any other cycle, exclusive of the cycle depicted on the barchart, defined subordinate to the horizontal mill in the machine tree(in this case, the spindle cycle 4434 identified in the cycle field 4426of FIG. 44). The bar chart editor 2962 d gleans the axis request optionsdirectly from the axis images for the horizontal mill that wereconstructed using the axis editor 2962 a. For example, referring againto FIG. 35, main slide advance and return requests were designated inboxes 3512 and 3514. The cross slide advance and return requests wouldhave been designated when the user constructed an axis image like theone in FIG. 35 for the cross slide subassembly axis. The spindlerequests would have been designated when the user constructed an axisimage for the spindle axis.

To specify a mill cycle, a user selects requests from the request menufor main slide advance, cross slide advance, main slide return and crossslide return. Each time a request is selected, the editor provides arequest box 4550, 4551, 4552 or 4553 in FIG. 45 under the REQUESTSheading. In addition, referring also to FIG. 46, the editor 2962 dprovides two blank sequence boxes to the right thereof under the CYCLETIME designation 4638, the sequence boxes divided by the LATCHdesignation indicating division between first and second sequences.Thus, there are two separate columns 4656, 4658 next to the requestboxes 4650-4653, a first sequence column 4656 and a second sequencecolumn 4658.

With all of the requests selected, the user begins to order the sequenceof requests by selecting the box in the first sequence column 4656corresponding to the first request in the cycle. In the present example,the sequence of requests is main slide advance, cross slide advance,main slide return and cross slide return. Therefore, the user wouldfirst select the box in the first sequence column corresponding to themain slide advance request in box 4650. The editor 2962 d would respondby placing a bar 4660 adjacent request box 4650 in the first sequencecolumn 4656.

Next, the user would select the box in the second sequence columncorresponding to the first request in the second sequence. In thepresent example, the first request in the second sequence is main slidereturn. The user would select the box in the second sequence column 4658corresponding to the main slide return. The editor 2962 d then places afunction bar 4662 in the selected box. At this point, the beginningrequests in the first and second sequences have been identified.

Next the user must select the second requests in the first and secondsequences. In the present example, the second request in the firstsequence is the cross slide advance request in request box 4651. Toplace a function bar for the cross slide advance request, the userselects box 4651 and drags a ghost image (not shown) of the box intofirst sequencing column 4656. To place the cross slide advance requestafter the main slide advance request, the user drags the ghost imageuntil it is clearly in the second half of the first sequence column4656. The user then releases the ghost image. To place the cross slideadvance request in front of the main slide advance request, the userwould release the ghost in the first half of the first sequence column4656. The ghost image is depicted as a cross hair to aid the user inthis process.

Referring again to FIG. 45, when the ghost image is released, the editor2962 d divides the first sequence column into first and second columns4564, 4565 using a vertical “done” line 4569 and provides a bar 4567corresponding to the cross slide advance request in box 4551. Inaddition, the editor 2962 d shortens bar 4560 so that bar 4560 endswhere bar 4567 begins, indicating that functions related to bars 4560and 4567 do not overlap. In other words, the function related to bar4560 is done at done line 4569.

A function bar for the cross slide return request may be placed in thesecond sequence in a similar fashion, but closer inspection reveals thatcorrect placement of the cross slice return function bar requiresanother technique.

In this case, the cross slide return action is expected to start as soonas the main slide reaches the intermediate cutter clear position CCP,and is expected to continue in parallel with the remainder of the mainslide return action until both actions are complete. So, referring againto FIGS. 45 and 46, before a function bar for the cross slide returnrequest can be correctly placed, it is necessary to indicate on barchart 4636 an intermediate “done” line bisecting the extent of the mainslide return function bar 4662 that represents the achievement of thecutter clear position CCP.

A bar chart editor 2962 d, although capable of gleaning information fromits functions about intermediate positions, is not capable ofdetermining which of many such positions are needed on the display 4536,while displaying all such positions is clumsy and detracts from theoverall usefulness of the display. In the preferred embodiment, a useris required to assist the editor 2962 d by choosing, on a function byfunction basis, which intermediate positions in each function need to beindicated on the display 4536. This is done through a function dialogthat is activated by clicking between the end triangles of a functionbar with the mouse-controlled cursor.

Referring again to FIGS. 45, 46 and 35, a user first selects the bar4562 associated with the main slide return request. A function dialoggleans information about outputs 3516 and composite positions from acontrol diagram 3574 of the main slide axis captured by an axis editor2962 b. The function dialog presents this information to a user in alist of “positions” traversed by the main slide returntrajectory—initial, intermediate, and final-in chronological order oftraversal. A user may select one or more intermediate, positions fordisplay. In this case, a user indicates that the composite position“cutter clear” CCP′ is needed on the display. The bar chart editor 2962d then creates a vertical line 4570, bisecting the main slide returnfunction bar 4662, and splitting the second sequence column 4658 intocolumns 4572 and 4573.

With reference to FIG. 45, a user can select a box at the intersectionof the row containing the cross slide return request box 4553 and thenewly created column 4573. The bar chart editor 2962 d then creates thecross slide return function bar 4574 in the selected box such that theleftmost end of bar 4574 meets the intermediate position line 4570 andthe rightmost end of bar 4574 meets the vertical line 4576.

Initially, all functions provided on a bar chart image 4536 using theeditor 2962 d are assumed to be normal functions (i.e. can be performedin either forward or reverse directions and can be repetitivelyperformed during manual operation in a single cycle). However, thepreferred editor 2962 d allows a user to specify non-reversible ornon-repeatable functions. This is accomplished by again activating thefunction dialog by clicking between the end triangles of a function barand making the appropriate selection in the function type section of thedialog. For example, by clicking bar 4567 and selecting “non-repeatable”in the function type section of the function dialog (not shown), thefunction associated with bar 4567 can be made non-repeatable. Similarly,a bar can be made non-reversible by activating the function dialog andselecting “non-reversible” in the function type section. Anon-repeatable function is designated by a bar having the number “1”adjacent its leftmost triangle. In FIG. 45, bar 4567 is so designated.Similarly, a “>” appearing adjacent to the leftmost triangle indicates anon-reversible function (see bar 4562). This information is gleaned bythe editor 2962 d for choosing function mapping in function modules (seeFIG. 49A).

Referring to FIG. 45, as a user creates different functions on the barchart image 4536, the editor 2962 d creates additional stop and yieldicons corresponding to various image elements. In particular, at thebeginning of each separate function 4560, 4567, 4562, 4574 the editor2962 d provides both a stop 4545 and a yield 4544 icon above the barchart grid. The stop 4545 and yield 4544 icons allow a user to conditionfunctions on the completion of other functions, cycles or other systeminput sequences. For example, to limit the possibility of spindledamage, it may be desired to make performance of the cross slide advancerequest contingent upon the horizontal mill spindle being in an “on”state. Either of the stop 4545 or yield 4544 symbols can be used forthis purpose.

To define contingencies for the cross slide advance request in requestbox 4551, a user may select yield icon 4544 which would provide acontingency screen 4574 allowing a user to add or remove contingenciesfrom a contingency list. Referring also to FIG. 47, one embodiment of acontingency screen would include two separate fields, one field 4780listing all possible machine contingencies. The other field, a CHOSENCONTINGENCY field 4781, would list selected contingencies. In addition,the screen 4702 would include a menu bar 4782 allowing a user to add anddelete contingencies to and from the CHOSEN CONTINGENCY field 4781. Tomake the cross slide advance contingent upon a spindle on state, theuser selects a spindle on contingence from field 4780. The editor thenadds the “spindle on” contingency to field 4781. Once a completecontingency list has been formed, the user saves the list andperformance of the cross slide advance of FIG. 45 is then conditionedupon all contingencies in the list associated with yield icon 4544 beingcompleted. The stop symbols 4545 are similar to the yield symbols inthat a list of contingencies can be formed which must be satisfied priorto continuing a sequence. However, whereas yield symbols 4544 apply onlyto functions beginning at the yield icon, a stop symbol 4545 applies toall functions beginning at or after the stop icon but before the end ofan associated half-cycle sequence. For example, contingencies referencedin a contingency list associated with stop symbol 4545″must be met atline 4576 and at line 4569.

In addition to contingencies on functions, sometimes it is necessary toput contingencies on the performance of the first and second sequencesof a cycle. This kind of contingency affects the performance of asequence independently of the contingencies on the functions making upthat sequence. In other words, these are contingencies on “cycling” acycle.

Contingencies specified using a stop sign 4545 are conditions needed inorder to initiate and continue performance of the first sequence of thecycle. In contrast, contingencies specified using a yield symbol 4544are conditions needed only to initiate performance of the first sequenceof the cycle, but are not required thereafter.

For example, a user may select yield icon 4544 associated with firstsequence request 4540 causing the bar chart editor to provide acontingency screen 4574 for the first sequence. By placing a “spindleon” condition in the CHOSEN CONTINGENCY field 4781, the user makesinitiation of the first sequence conditional upon the spindle being inan “on” state. This contingency is in addition to a similar, butdifferent, contingency placed on the cross slide advance request, whichis a function performed as a part of the first sequence.

Both the function and first sequence contingencies apply the same“spindle on” condition, but the meanings are different and, what's more,complementary. Sequence contingencies are used to avoid initiating,continuing, or resuming performance of a sequence of operations thathave little or no hope of being completed successfully or safely. Inthis case, if the spindle state is not “on” when a first sequencerequest is made, there is little or no hope that the spindle will be“on” when the cross slide advance request requires it to be so.Specifically, the first sequence contingency avoids advancing the mainslide when it is already known that the cross-slide cannot advance. Thisavoids unnecessary machine activity that wastes time, energy, and mayrequire the attention of a machine operator to undo before that cyclecan be restarted. Sequence contingencies specified using a stop symbolalso prevent unintended “spontaneous” resumption of sequence performanceand, therefore, any requested functions that may have stopped due to arelated function contingency, should a required condition that was lostsuddenly be rectified.

Similarly, second sequence contingencies may be specified using stop andyield symbols associated with a second sequence request icon 4541, whilesequence contingencies may be specified common to both sequences usingstop and yield symbols associated with whole cycle request icon 4542.

Referring again to FIG. 51, preferably, after a complete cycle has beendefined using the bar chart editor 2962 d, the editor 2962 d gleansinformation for each individual function from the bar chart image 4536and assigns buckets, start positions, and safeties to each functionaccording to FIG. 50 attributes table 5031. Every start position isuniquely named and placed in a bucket M while every safety designatedusing icons 4544 or 4545 is placed in a bucket O.

Referring to FIG. 52, to assign buckets for all functions, the editor2962 d starts with the first function in a bar chart, labels thatfunction an original observing function at block 5252, and worksbackward to bucket all other cycle functions until it reaches theinverse of the observing function. Referring also to FIG. 45, to assignbuckets for functions 4560, 4567, 4562 and 4574, the editor 2962 d wouldfirst label function 4560 the observing function. Then at block 4553,the editor 2962 d would label the function prior to function 4560, inthis case function 4574, as the observed function. At block 4554, theeditor 2962 d assigns the observed function 4574 to a bucket of theobserving function 4560 according to the attributes table 5031illustrated in FIG. 50. The bucketing process is explained below withreference to FIG. 53.

In FIG. 52, at block 5255, the editor 2962 d labels the function priorto the instantaneous observed function as the next observed function. InFIG. 53, function 5362 would be labeled the observed function. Atdecision block 5256 the editor 2962 d determines if the observedfunction 5362 is the inverse of the observing function 5360. Where theobserving function 5362 is not the inverse, the editor 2962 d returns toblock 5254 and buckets the observed function. The editor 2962 drepetitively cycles through blocks 5254-5256 until the observed functionis the inverse of the observing function.

In a preferred embodiment, the observed function 5362 is the inverse ofobserving function 5360 and therefore, at decision block 5256, theeditor 2962 d branches to block 5257 and labels the function prior tothe instantaneous observing function as the observing function. In thepresent case, function 4574 would be labeled the observing function. Atdecision block 5258, the editor 2962 d determines if the observingfunction is the original observing function. If this condition is met,the editor 2962 d stops the bucketing process. If the observing functionis not the original observing function, the editor 2962 d passes controlback up to block 5253 and begins the process over again. Thus, theeditor 2962 d assigns to buckets all of the needed required functionsfor every function in a cycle.

Referring now to FIG. 53, the bucketing process of block 5254 isillustrated as process 5360. To bucket an observed function, the editor2962 d first determines whether or not the observed function is stablerelative to the observing function at decision block 5362.

Where the observed function is not stable, the editor 2962 d determinesif the observed function is canceled by the observing function orcanceled by some other function at decision block 5370. Where the nextfunction is canceled by some other function, the editor 2962 d nextdetermines whether or not the observed function is in the samehalf-cycle as the observing function at block 5378. Where the observedfunction is in the same half-cycle as the observing function, atdecision block 5379 the editor 2962 d determines whether or not theobserved function incorporates a position or a latch. Where the observedfunction incorporates a position, at block 5380 the editor 2962 dbuckets the observed function as type A. Referring also to FIG. 49a,assigning a function to a bucket entails placing a unique name for thefunction in the appropriate list in the module list specificationsection 2342 of the function template 2336 associated with the observingfunction. In this case, where a function is placed in bucket A, thefunction is unstable, is canceled by the observing function, is in thesame half-cycle as the observing function and incorporates a positionand therefore would be placed in module list specification. Similarly,as other functions are assigned to buckets, they are placed in otherlists in the module list specification section 2342.

After blocks 5379 and 5380, at block 6000 the editor 2962 d determinesif the observed function incorporates a latch. Note that a function canincorporate both a latch and a position. Where the observed function isnot stable, is canceled by a function other than the observing function,is in the same half-cycle as the observing function and incorporates alatch, at block 5381 the editor 2962 d assigns the observed function tobucket C.

Referring again to decision block 5378, where the observed function isnot stable, is canceled by a function other than the observing function,and is not in the same half-cycle as the observing function, the editor2962 d passes control to decision block 5382 to determine whether or notthe observed function incorporates a position. Where the observedfunction incorporates a position, the editor 2962 d assigns the observedfunction to bucket B at block 5383. At blocks 6002 and 5384, where theobserved function incorporates a latch, the editor 2962 d assigns theobserved function to bucket D.

Referring again to decision block 5370 where the observed function isnot stable but is canceled by the observing function, the editor 2962 dpasses control to decision block 5371 and determines whether or not thefunction is in the same half-cycle as the observing function. Where theobserved function is in the same half-cycle as the observing function,the editor 2962 d determines whether or not the observed functionincorporates a position or a latch at decision block 5372. Where theobserved function incorporates a position, the editor 2962 d assigns theobserved function to bucket G at block 5374. Where the observed functionincorporates a latch, the editor 2962 d assigns the function to bucket Eat blocks 6004 and 5375.

Referring again to decision block 5371, where the observed function isnot stable, is canceled by the observing function, and is in thehalf-cycle opposite the observing function, the editor 2962 d passescontrol to decision block 5373 to determine whether or not the observedfunction is a position. Where the observed function incorporates aposition, the editor 2962 d assigns the function to the F bucket atblock 5376 and where the observed function incorporates a latch theeditor 2962 d assigns the function to bucket H at blocks 6006 and 5377.

Referring once again to decision block 5362, where the observed functionis stable, the editor 2962 d determines whether or not the observedfunction is in the same half-cycle as the observing function at decisionblock 5363. Where the observed function is in the same half-cycle as theobserving function the editor 2962 d determines whether or not theobserved function incorporates a position at block 5364. Where theobserved function incorporates a position, the editor 2962 d assigns thefunction to bucket I at block 5366. Where the observed functionincorporates a latch the editor 2962 d assigns the function to bucket Kat blocks 6008 and 5367.

Referring again to decision block 5363, where the observed function isstable and is in the half cycle opposite the observing function theeditor 2962 d determines whether or not the observed functionincorporates a position at block 5365. Where the observed functionincorporates a position, the editor 2962 d assigns the function tobucket J at block 5369. Where the observed function incorporates a latchthe editor 2962 d assigns the function to bucket L at blocks 6010 and5368.

After all of the necessary functions in a cycle have been assigned tobuckets and added to appropriate lists by the editor 2962 d, the editoralso gleans from the control diagram 4536 in FIG. 45 which half-cyclethe function is in. Referring to FIG. 49B, this information is used tolabel contact 4950. In addition, this information is used at compiletime with the XPO and XPC pseudoinstructions as explained above.

After a user completes the bar chart for the mill cycle includingrequest designation, proper bar sequencing and proper contingencydesignations, the user must then go back to the control panel editor2962 c and select the next cycle to be defined. Referring to FIG. 44, inthe present example the user selects the spindle icon 4434 and reentersthe bar chart editor 2962 d to define the spindle cycle. The spindlecycle would include two requests, a “spindle on” request and a “spindleoff” request. The spindle on request would constitute the first sequenceand the spindle off request would constitute the second sequence. Aswith the mill cycle, the user would construct a complete bar chart likethe one in FIG. 45, including requests, bars and contingencies for thespindle cycle. During construction, the editor 2962 d would continue toglean information required to populate modules and create new modulesand to assign buckets as described above.

After complete bar charts have been constructed for each cycleidentified in CYCLE field 4426, if desired, the user can then definemanual control devices and tie those devices to specific requests in thebar charts.

In accordance with the example, it will be assumed that a user requiresfour separate manual push buttons on the horizontal mill control panel,one button each for the main and cross slide advance requests and onebutton each for the main and cross slide return requests. While buttonscould be included for the spindle on and spindle off requests, for thepurposes of this explanation it will be assumed that they are notneeded. To define a push button for the main slide advance request, theuser selects the CONTROLS option from menu bar 4422 which would providea complete list of all requests associated with the cycles identified inthe CYCLE field 4426. In the horizontal mill example, the request listincludes “main slide advance”, “main slide return”, “cross slideadvance”, “cross slide return”, “spindle on”, “spindle off”, and “wholecycle”, “first sequence” and “second sequence” requests for both themill and spindle cycles. To designate a main slide advance button theuser selects the main slide advance request from the list. The editor2962 c then provides a button icon 4486 labeled “main slide advance”.

In a similar fashion, the user selects the CONTROLS option three moretimes, each time selecting a different possible request, the threeselected requests being “cross slide advance”, “main slide return” and“cross slide return”. Each time a different request is selected, theeditor 2962 c provides a new icon 4487, 4488, 4489 labeled accordingly.At this point all of the manual control buttons have been defined andassociated with different requests.

To define indicator lights, the user selects the LIGHTS option from bar4422. The editor 2962 c provides a list of possible limiting positionsassociated with the requests in the mill and spindle cycles. The userselects a limiting position and then the editor 2962 c provides anassociated light icon. In FIG. 44, two light icons are illustrated, one4492 for the main slide return and another 4494 for the cross slidereturn.

As with the machine 2962 a and axis 2962 b editors, while a user isconstructing a control panel image and corresponding bar chart imagesusing the control panel 2962 c and bar chart 2962 d editors, the editors2962 c and 2962 d are simultaneously gleaning information from theimages to further develop the template-based machine tree according tothe process shown in FIG. 32. Thus, additional modules are created andexisting modules are populated until all required images have beencompleted.

With all of the modes, manual control and indicator light devicesdefined and all of the cycles corresponding to the horizontal milldefined, the editors have all the information required to provide LLlogic to control the horizontal mill. To provide information requiredfor all of the machine components, the user would step through editingwith the axis 2962 b, control panel 2962 c, and bar chart 2962 d editorsfor all machine components.

After all required physical and operational characteristics of machinecomponents are completely defined using the editors described above, theuser would instruct the programming terminal to compile the entiretemplate tree. Compilation is relatively simple and is depicted in FIG.48. Initially, at block 4840, the compiler expands all child modulesinto specifications in parent modules. For example, referring again toFIGS. 23 and 24, the master control panel -module 2406 is placed in themachine module 2398 where the master control panel is referenced at2300. Similarly, all axis modules (herein the module name “air”) areexpanded into the machine module 2398 in place of the module listspecification named Axis 2302 and all indexer modules (herein the modulenamed “T1”) are expanded into the machine module 2398 in place of themodule list specification named Indexer 2304. The compiler works its waythrough the entire template-based machine tree, including portionsprovided by the axis 2962 b, control panel 2962 c and bar chart 2962 deditors until all child modules have been expanded into theirreferencing parent modules.

In FIG. 48, at block 4850 the compiler allocates programmable controllermemory for the modules and assigns memory addresses to fully qualifiednames defined by data definition statements in the modules. Next, atprocess block 4841, the compiler resolves the symbolic expressions intofully-qualified names. For example, a symbolic expression for a pushbutton of a master control panel may be “$.MasterStartPB”. In thepresent example, this symbolic expression would expand into the fullyqualified name “AB1.MasterControlPanel.MasterStartPB”. Similarly, theleft horizontal work-unit of the fourth station in the present examplewould have the fully qualified name “AB1.T1.S4.LH” wherein LH stands for“left horizontal”, S4 for “the fourth station”, T1 for “the transfer”and AB1 for “the machine” generally.

After all the symbolic expressions have been expanded into fullyqualified names, at block 4842 the extended instructions such as AND andOR lists are replaced with LL logic. Thus an AND list macrocorresponding to a list including ten entries will be replaced by a tencontact series set of LL instructions, each contact corresponding to adifferent list entry. Similarly, OR list macros would be replaced with aset of LL instructions expanded in parallel.

Next, at block 4843 the compiler would compile pseudoinstructions XPC,XPO and OTX, removing LL logic from some LL rungs and expanding logic inothers depending on job specific requirements. After block 4843, allthat remains is a control program consisting entirely of conventional LLlogic that can be used by a programmable logic controller to control theindustrial process of a machine.

It should be appreciated by those of ordinary skill in the art that thedescription herein is given only by way of example and that variousmodifications and additions might be made, while still coming within thescope of the invention. In particular, while the present template-basedlanguage has been developed for use in LL programming, othertemplate-based languages could be developed for use with otherindustrial controller programming languages such as state diagramprogramming. The important aspect of the present language is not that itrelates to LL, but rather the realization that extensions to normalprogramming language logic itself in conjunction with extensions thatare separate from the language logic can be used to provide trulyreusable programming logic that can be tailored to job-specificrequirements. In addition, while the exemplary template set detailedabove was specifically designed for the metal removal industry, it isanticipated that other template sets that account for industry specificidiosyncrasies will be developed for other industries, and the presentinvention is meant to cover all other such template sets.

Moreover, while the description above described how computer editors canact as interfaces to facilitate programming, it is contemplated that auser could construct a template-based machine tree and compile a programwithout the use of a computer editor. In other words, using a templateset, a user could designate and populate modules by hand and thencompile the modules as in FIG. 48.

Furthermore, while preferred editors are described herein, any type ofcomputer editor could be used to aid a user in programming using thetemplate language. The important aspect of any editor is that the editorallow the user to input information from which the editor can glean asubset of information required to designate and populate requiredmodules. In addition, while the present invention is described in thecontext of four editors, the inventive template language could be usedwith more special editors provided for specific applications or in thealternative, one editor could be used separately to provide LL logic fora single portion of a machine tree.

Visualization of Schematics

The Designer Studio also utilizes the ECDB to ascertain typedconnections (electrical, pneumatic, network, . . . ) within a controlassembly or interfacing from/to a Control Assembly. This visualizationenables a user to clearly see disparities between the connectionsimproving the integrity of the resultant system.

Bill of Materials

The system also supports detailed bill of material informationvisualization. Controlled Resources contain properties of the resourcecontrolled by the control assembly that place requirements (i.e., addconstraints) on the structure of the assembly that facilitate moreprecise renderings of the enterprise control system.

For example, a clamp1 controlled resource has a safety constraint whichrequires a failing clamp to always fail in the open position.

Requests or Conditions

A request for an operation (optionally with confirmation) or request fora status of the external world determines how to handle complicatedactions (initialization, robot protocols, . . . ). For example, todetermine if a part is present, control logic must be defined toSensePart with a request status returned to unambiguously determine if apart has been sensed or not.

The placement of the timing chart and the control request bar chart inproximal position facilitates an optimal user experience. Automaticordering of control commands based on the prescribed order from a timingdiagram is a unique and powerful feature in accordance with a preferredembodiment.

EC Integration with External Data Models

(Re)Use resources created within the mechanical modeling environment todetermine the Mechanical Resources that need to be controlled.

Transform the process description (i.e., sequence of activities that theresources perform) to a timing diagram.

EC Control System Design

Provides catalog of reusable control sub-system components: ControlAssembly™ Type (see below for what is in a control assembly)

Allows user to create Control Assemblies™ that correspond to frequentlyused control subsystem design patterns.

Allows user to sequence the Requests of Control Assembly Instances(i.e., Request/Timing Diagram)

Allows user to connect the Control Assembly Instances electrically,pneumatically, and hydraulically (i.e., “control system-wide schematic”)

Allows user to configure exceptional behavior (e.g., manual emergencypower recovery).

Allows user to layout HMI

EC Simulation

Visualization the LL execution

Visualization the current step(s) the machine is waiting on

Visualization the “control process”, i.e., animate the Timing Diagram

Use generated code via SoftLogix to animate in 3-D the workcell machinesthat simulate the process and the subsequent creation of the product

Note: in EC all these simulations run off the same data model.

EC Control System Implementation

Bill of materials (from RS Wire Schematics)

Make control system bill of materials and control system processavailable to the Machine and Process designers (i.e., export to CNext)

Code generation

Diagnostics Generation

HMI (Visualization) Generation

EC Control System Maintenance

Diagnostics

Keeping control system design consistent with Product, Process, andMachine Design

Password protect to provide restricted access to LL and the capabilityto record and changes that are made to the LL that must be reengineeredinto the design.

In an enterprise control system in accordance with a preferredembodiment a user must first abstract enterprise activities that areutilized to assemble parts into their basic steps. No machine or controlresources are necessary for this definition process. An example inaccordance with a preferred embodiment will be utilized to illustratethis process. To weld a part of a car door assembly together, a partmust be loaded, the second part of the door must be loaded (clamped),the first welding operation is performed and the second weldingoperation is performed. Finally, the welded door assembly is unloadedand transported to its next station.

Conversion of CATIA Activities Data to/from Timing Diagrams

Overview

Rockwell Automation and Dassault Systems are collaborating on a set oftools to design and implement production machinery. This collaborationinvolves storing both structural information and process information inDassault's CNext product line. Dassault Systems uses a different modelto store process information in CNext than is used in RockwellAutomation's Control Designer Studio. In order to exchange data betweenDassault and Rockwell, a Data Interchange File Format has beennegotiated. Each company is responsible for converting between its owndata stores and the Data Interchange File Format. This documentdescribes the conversion between the Data Interchange File Format andRockwell's Virtual Control Model database.

Data Interchange Format

The Data Interchange File Format consists of a text file containing onlyASCII text divided into lines. Each line is either blank, or it containsone of the keywords (Activities, ActivityResources,ActivityPredecessors, ActivityAttributes, StructuralComponents) or itcontains a series of comma-separated data fields appropriate to thepreceding keyword. The document defining the fields and their formatsfollows:

StructuralComponents

StructuralComponentID,PartOf,WorkcellID,Label ,Class

string,string,string,string,string

12345,0,1 ,EsI,Support

23456,12345,1,Clampset1,Clampset

Activities

ActivityID,ParentActivityID,ActivityLabel,ActivityType,ActivityDuration

string,string,string,string,numeric

ActivityResources

ActivityID,StructuralComponentID

string,string

ActivityPredecessors

ActivityID,PredecessorActivityID

string,string

ActivityAttributes

ActivityID,AttributeKey,AttributeValue

string,string,string

(a blank line ends one table and begins another)

(there may be as many sections as needed, and the same table may appearseveral times in a file)

Importing into Virtual Control Model

In the interests of modularity, the function of importing data from thistext file into the Rockwell VCM has been split into 2 steps. In thefirst step, the text file is parsed and an intermediate text stream ofSQL statements is created. In the second step, the stream of SQLstatements is executed against the VCM database.

Parsing the Input File

The file parsing tool is a Perl script which implements a state machinewith the 2 states READ_TABLE_NAME and READ_DATA. It begins in stateREAD_TABLE_NAME, in which it reads lines of input (ignoring blank lines)until it finds one of the valid keywords. When it finds a keyword, itsets up the expected names and types of data to follow and switches tostate READ_DATA. If what it finds is not a valid keyword, it exits afterlogging an error.

In the READ_DATA state the tool reads successive lines of data, checksfor the expected number of fields, and emits one SQL statement for eachline read. The SQL statements are all INSERT statements, each insertingone row of data into the correspondingly-named table in the VCMdatabase. When the tool reads a blank line, it changes state toREAD_TABLE_NAME. End of file terminates the tool.

ODBC Tool

The tool that executes SQL statements against a database is a Perlscript employing the Win32::ODBC extension. It is invoked from thecommand line with an argument specifying the name of the ODBC datasource to be opened. Then it reads its standard input for SQLstatements, each of which is executed in turn, and the success orfailure of each statement is checked. If any statement fails, the entireprocess terminates and an error message is logged. After all statementshave been executed, the data source is closed and the processterminates.

Conversion to Timing Diagrams

After execution of the preceding processing, the data from theInterchange File resides in a set of intermediate tables in the VCMdatabase. Further processing is required to convert them to the formatused by Rockwell's tools to display Timing Diagrams to the user. All ofthis processing is carried out in a single tool, because it isinterrelated, with later steps depending on the results of earliersteps. The processing begins with establishment of an ODBC connection tothe VCM data source. An SQL query is executed to Find all top levelActivities (usually only one).

Timing Diagram Creation

A Timing Diagram is created for the specified Activity, using the Createa Timing Diagram query.

Edge Creation

Every Timing Diagram has at least one Edge, the left Edge. The Create anEdge query is executed to create the left Edge.

Request Creation

The Find all Requests on this Timing Diagram query is executed toidentify Activities that will map to Requests. Then the Create aCNextRequest query is used for each of the Requests. For each Request,running a Count subsidiary Activities query determines if this Requestrequires a subsidiary Timing Diagram. If it does, BarChart creation,Edge creation, and Request creation are called recursively. This will goon until there are no more subsidiary Activities detected. After asubsidiary Timing Diagram has been created, it is necessary to executeUpdate SubBarChartID in CNextRequest.

Associating Requests with Edges

After all the Activities on a Timing Diagram have been created, theymust be organized by relating them to Edges. As many Edges will becreated as are needed to organize all the Requests on the TimingDiagram. The processing begins with executing Find all Requests on leftEdge of Timing Diagram. Then, for each Request found, Update LeftEdge ofRequests with no Predecessors is executed. At this point Create an Edgecan be executed to create the new right Edge. Following this a loop isexecuted, where each iteration begins with executing Find all Requestsfor next Edge and continues by executing Update LeftEdge of otherRequests and Create an Edge if any Requests were found. The loopterminates when no more Requests can be found.

SQL Queries

All of the database processing is carried out by executing SQLstatements under control of a script or program. This guaranteesportability of the processing between different database servers. Thequeries are described in the following sections. The words beginningwith $ are variables that are substituted into the queries before theyare executed. Most of the queries are self-explanatory, but the morecomplex ones are accompanied by textual clarification.

Find all top level Activities

SELECT * FROM Activities WHERE ParentActivityID=‘0’

Create a Timing Diagram

INSERT INTO BarCharts

(BarChartID, BarChartStrng, BarChartDescr, ModeID)

VALUES ($BarChartID, ‘$barChartStrng’, ‘From CATIA’, 1)

Create an Edge

INSERT INTO Edges (EdgeID, EdgeNum, BarChartID)

VALUES ($EdgeID, $edgecount, $BarChartID)

Find all Requests on this Timing Diagram

SELECT * FROM Activities WHERE ParentActivityID=‘$ParentActivityID’

Activities give rise to both BarCharts and CNextRequests, depending ontheir position in the hierarchy. A top level (parentless) Activity isalways a BarChart, and a lower level Activity is always a Request, butif the lower level Activity has children, it will give rise to asubsidiary BarChart as well as a Request.

Create a CNextRequest

INSERT INTO CNextRequests

(RequestID, LeftEdge, BarChartID, RequestOrder, Activity, Resources,SubBarChartID)

VALUES ($RequestID, 0, $BarChartID, 0, ‘$activityID’, NULL, 0)

Count subsidiary Activities

SELECT COUNT(*) AS ChildCount FROM Activities

WHERE ParentActivityID=‘$activityID’

Update SubBarChartID in CNextRequest

UPDATE CnextRequests

SET SubBarChartID=$newBarChartID

WHERE RequestID=$RequestID

Find all Requests on left Edge of Timing Diagram

SELECT * FROM Activities

WHERE Activities.ParentActivityID=‘$ParentActivityID’

AND NOT EXISTS (SELECT * FROM ActivityPredecessors

WHERE Activities.ActivityID=ActivityPredecessors.ActivityID)

This query may be paraphrased as “select those Activities belonging tothis BarChart and lacking a predecessor Activity”.

Update LeftEdge of Requests with no Predecessors

UPDATE CnextRequests

SET LeftEdge=$edgeID

WHERE CNextRequests.Activity=‘$ActivityID’

Find all Requests for next Edge

SELECT R2.RequestID

FROM CNextRequests AS R1, CNextRequests AS R2, ActivityPredecessors ASAP1

WHERE R1.LeftEdge=$oldEdge

AND AP1.PredecessorActivityID=R1.Activity

AND R2.Activity=AP1.ActivityID

This query may be paraphrased as “select those Requests whosepredecessor Activity mapped to a Request linked to the preceding Edge”.

Update LeftEdge of other Requests

UPDATE CnextRequests

SET LeftEdge=$edgeID

WHERE CNextRequests.RequestID=$RequestID

Select BarChart for export

SELECT * FROM [BarCharts] WHERE BarChartID=$BarChartID

Create Ordered Edge List

SELECT * FROM Edges

WHERE BarChartID=$BarChartID

ORDER BY Edges.EdgeNum

Select Requests for export

SELECT * FROM Requests

WHERE Requests.LeftEdge=$EdgeID

ORDER BY Requests.RequestOrder

Lookup Request Attributes

SELECT ControlAssemblyInstances.Label AS InstanceLabel,

DCCActions.Label AS ActionLabel,

DCCElementsTimes.Time

FROM Requests,

ControlAssemblyinstances AS Cai,

DCCActions,

DCCElementsTimes

WHERE Requests.RequestID=$RequestID

AND Requests.ControlAssemblyInstanceID=Cai.ControlAssemblyInstanceID

AND DCCActions.DCCActionsID=Requests.DCCActionsID

AND DCCElementsTimes.DCCActionsID=Requests.DCCActionsID

The first step in designing a control system utilizing an enterprisesystem in accordance with a preferred embodiment is presented below. Theexample from an actual car manufacturing station for a rear quarterpanel assembly is utilized to assist one of ordinary skill in the art tomake and use a preferred embodiment without undue experimentation.

A control engineer initiates the Rockwell Automation Enterprise ControlsDesigner Studio in accordance with a preferred embodiment to initiatethe process. The engineer creates a new project by selecting the newproject and gives it an appropriate name, like NEWPROJECT. This activitycauses the system to load the machine resources that require control tobe loaded from the existing CAD database. A process description is alsoloaded from the existing CAD database.

Data Conversion to/from the ECDB

One of the key tasks in creating an Enterprise Control Database (ECDB)is the creation of a uniform set of data structures and a set of mappingprocedures to take data from disparate sources and import it into theECDB. Some of these data sources include structural information (CADmodels, etc.) and process information. In accordance with a preferredembodiment moves data into the ECDB and creates a Data Interchange FileFormat (DIFF) file, and then use tools that can populate a set ofdatabase tables from information in the DIFF.

The ECDB also supports the export of data in a variety of formats thancan then be used to generate input to a variety of design analysis andsynthesis tools, such as Rockwell Automation's Control Designer Studioor Dassault's CNext process modeling system.

The Data Interchange File Format consists of a text file containing onlyASCII text divided into lines. Each line is either blank, contains oneof the keywords, or contains a series of comma-separated value (CSV)data fields appropriate to the preceding keyword. Because of theflexibility of CSV, the number of fields and their formats will growover time to allow very rich structure.

The currently supported table keywords are: (Activities,ActivityResources, ActivityPredecessors, ActivityAttributes,StructuralComponents). These tables are defined below, where the nthelement of the “ColumnValues” list is the storage format of the tablecolumn whose name is the nth element of the “ColumnNames” list. Thetable definitions follow:

Table=StructuralComponents

ColumnNames=StructuralComponentID,PartOf,WorkcellID,Label,Class

ColumnValues=string ,string ,string ,string,string

Table=Activities

ColumnNames=ActivityID,ParentActivityID,ActivityLabel,ActivityType,ActivityDuration

ColumnValues=string,string,string,string,numeric

Table=ActivityResources

ColumnNames=ActivityID,StructuralComponentID

ColumnValues=string,string

Table=ActivityPredecessors

ColumnNames=ActivityID,PredecessorActivityID

ColumnValues=string,string

Table=ActivityAttributes

ColumnNames=ActivityID,AttributeKey,AttributeValue

ColumnValues=string,string,string

This file format supports an arbitrary number of database tables. Theformat is to be interpreted as follows:

A blank line ends one table and begins another

The first non-blank line after a blank line denotes the table name

Subsequent non-blank lines denote data in CSV format

There may be as many sections as needed, and the same, table may appearseveral times in a file. An example DIFF is shown below, with keywordshighlighted in bold:

StructuralComponents

12345,0,1,EsI,Support 23456,12345,1,Clampset1,Clampset

Activities

12345,4367,Load,,45

ActivityResources

12345,23456

ActivityPredecessors

Clampset1,Clampset2

ActivityAttributes

This file format is illustrative only. Extensions (via additionalcolumns) can be added to particular database tables, and new tablesadded, to support such concepts as Interlocks (triggering events) andSafeties (enabling events).

In the interests of modularity, the function of importing data from theDIFF into the ECDB has been split into two steps. In the first step, theDIFF file is parsed and an intermediate text stream of SQL statements iscreated. In the second step, the stream of SQL statements is executedagainst the ECDB database.

Step 1: Parsing the DIFF and Generating SQL

The file parsing tool has been implemented as a Perl script whichimplements a state machine with the two states READ_TABLE_NAME andREAD_DATA. Execution of the Perl script begins with the program in stateREAD_TABLE_NAME, in which it reads lines of input (ignoring blank lines)until it finds a keyword. If the keyword is not a member of the validkeywords, the program logs an error and exits. Otherwise, after findinga valid keyword, the script program initializes a number of variablesthat define the expected names and types of data to follow. The programthen switches to state READ_DATA.

In the READ_DATA state the tool reads successive lines of data, checksfor the expected number of fields, and emits one SQL statement for eachline that has been read from the DIFF. The SQL statements are all INSERTstatements, each inserting one row of data into thecorrespondingly-named table in the ECDB.

When the Perl script program reads a blank line, it changes its stateback to READ_TABLE_NAME.

Reading an End of File (EOF) terminates execution.

Step 2: Executing the Stream of SQL Statements Against the ECDB

The tool that executes SQL statements against a database is a Perlscript employing the Win32::ODBC extension. It is invoked from thecommand line with an argument specifying the name of the ODBC datasource to be opened. Then it reads its standard input for SQLstatements, each of which is executed in turn, and the success orfailure of each statement is checked. If any statement fails, the entireprocess terminates and an error message is logged. After all statementshave been executed, the data source is closed and the processterminates. The standard input stream for this program is usually thestandard output of the Perl program of Step 1 above.

For each SQL query attempted, the program checks the return status. Ifthe return status is an error state, the program returns the error textand terminates. Otherwise, the program terminates when all SQLstatements have been successfully executed against the ECDB.

At this point, the data has been successfully placed in the EnterpriseDatabase in a canonical format, and can now be accessed by a variety oftools. In general, data translation is required from the ECDB internalformat to a format that is acceptable to a specific tool. For example,Rockwell's Designer Studio program uses a format called Timing Diagramsto denote the activities performed by resources and bar charts to denotethe requests made to the resources.

Conversion from ECDB to Timing Diagrams

The processing required for exporting data from the ECDB in a formatcompatible with Rockwell's tools to display Timing Diagrams to the useris described. All of this processing is carried out utilizing a singletool that processes the results of earlier steps. The processing beginswith establishment of an ODBC connection to the ECDB data source. A SQLquery is executed to Find all top level Activities (usually there isonly one).

Timing Diagram Creation

A Timing Diagram is created for the specified Activity, using the Createa Timing Diagram query. Code in Perl is shown below for convertinginformation from CATIA process description to a timing diagram for useby the ECDB.

# prepare connection to Machine Resource DB $db = new Win32::ODBC(“VCM”)∥ die $!; # prepare connection to Machine Resource DB $db = newWin32::ODBC(“VCM”) ∥ die $!; =head2 mainline #for each parentlessActivity CreateBarChart recursively =cut my $query = “SELECT * FROMActivities WHERE Activities.ParentActivityID = ‘0’”; my(@rows) = (); if(! $db−>Sql($query)) {   # read the entire set of rows   while($db−>FetchRow())   {      # store result as a list of hashes      push@rows, {$db−>DataHash()};   } } else {   ReportSQLError($query); } #iterate through the array of rows, with no further DB access my $row;for each $row (@rows) {   &CreateBarChart($row−>{“ActivityLabel”},$row−>{“ActivityID”} ); } $db−>Close(); # end of mainline #for eachparentless Activity CreateBarChart recursively =cut my $query =“SELECT * FROM Activities WHERE Activities.ParentActivityID = ‘0’ ”;my(@rows) = (); if (! $db−>Sql($query)) {   # read the entire set ofrows   while ($db−>FetchRow())   {      # store result as a list ofhashes      push @rows, {$db−>DataHash()};   } } else {  ReportSQLError($query); } # iterate through the array of rows, with nofurther DB access my $row; foreach $row (@rows) {  &CreateBarChart($row−>{“ActivityLabel”} , $row−>{“ActivityID”} ); }$db−>Close(); # end of mainline

Edge Creation

Every Timing Diagram has at least one Edge, the left Edge. The Create anEdge query is executed to create the left Edge. A summary of the stepsin the actual execution code follows:

3. CreateBarChart

4. CreateEdge

5. for each Activity with this parent

6. CreateCNextRequest

7. find Activities with this parent with no ActivityPredecessors

8. AssignLeftEdge

9. CreateEdge

10. while any unassigned Activities with this parent remain

11. for each ActivityPredecessor pointing to any Activity on previousedge

12. AssignEdge

13. CreateEdge

14. return BarChartID

Request Creation

The Find all Requests on this Timing Diagram query is executed toidentify Activities that will map to Requests. Then the Create aCNextRequest query is used for each of the Requests. For each Request,running a Count subsidiary Activities query determines if this Requestrequires a subsidiary Timing Diagram. If it does, BarChart creation,Edge creation, and Request creation are called recursively. This will goon until there are no more subsidiary Activities detected. After asubsidiary Timing Diagram has been created, it is necessary to executeUpdate SubBarChartID in CNextRequest.

Associating Requests with Edges

After all the Requests on a Timing Diagram have been created, they mustbe organized by relating them to Edges. As many Edges will be created asare needed to organize all the Requests on the Timing Diagram. Theprocessing begins with executing Find all Requests on left Edge ofTiming Diagram. Then, for each Request found, Update LeftEdge ofRequests with no Predecessors is executed. At this point Create an Edgecan be executed to create the new right Edge. Following this a loop isexecuted, where each iteration begins with executing Find all Requestsfor next Edge and continues by executing Update LeftEdge of otherRequests and Create an Edge if any Requests were found. The loopterminates when no more Requests can be found.

Export of Timing Diagrams

SQL Queries

All of the database processing is carried out by executing SQLstatements under control of a script or program. This guaranteesportability of the processing between different database servers. Thequeries are described in the following sections. The words beginningwith $ are variables that are substituted into the queries before theyare executed. Most of the queries are self-explanatory, but the morecomplex ones are accompanied by textual clarification.

Find all top level Activities

SELECT * FROM Activities WHERE ParentActivityID=‘0’

Create a Timing Diagram

INSERT INTO BarCharts

(BarChartID, BarChartStrng, BarChartDescr, ModeID)

VALUES ($BarChartID, ‘$barChartStrng’, ‘From CATIA’, 1)

Create an Edge

INSERT INTO Edges (EdgeID, EdgeNum, BarChartID)

VALUES ($EdgeID, $edgecount, $BarChartID)

Find all Requests on this Timing Diagram

SELECT * FROM Activities WHERE ParentActivityID=‘$ParentActivityID’

Activities give rise to both BarCharts and CNextRequests, depending ontheir position in the hierarchy. A top level (parentless) Activity isalways a BarChart, and a lower level Activity is always a Request, butif the lower level Activity has children, it will give rise to asubsidiary BarChart as well as a Request.

Create a CNextRequest

INSERT INTO CNextRequests

(RequestID, LeftEdge, BarChartID, RequestOrder, Activity, Resources,SubBarChartID)

VALUES ($RequestID, 0, $BarChartID, 0, ‘$activityID’, NULL, 0)

Count subsidiary Activities

SELECT COUNT(*) AS ChildCount FROM Activities

WHERE ParentActivityID=‘$activityID’

Update SubBarChartID in CNextRequest

UPDATE CnextRequests

SET SubBarChartID $newBarChartID

WHERE RequestID=$RequestID

Find all Requests on left Edge of Timing Diagram

SELECT * FROM Activities

WHERE Activities.ParentActivityID=‘$ParentActivityID’

AND NOT EXISTS (SELECT * FROM ActivityPredecessors

WHERE Activities.ActivityID=ActivityPredecessors.ActivityID)

This query may be paraphrased as “select those Activities belonging tothis BarChart and lacking a predecessor Activity”.

Update LeftEdge of Requests with no Predecessors

UPDATE CnextRequests

SET LeftEdge=$edgeID

WHERE CNextRequests.Activity=‘$ActivityID’

Find all Requests for next Edge

SELECT R2.RequestID

FROM CNextRequests AS R1, CNextRequests AS R2, ActivityPredecessors ASAP1

WHERE R1.LeftEdge=$oldEdge

AND AP1.PredecessorActivityID=R1.Activity

AND R2.Activity=AP1.ActivityID

This query may be paraphrased as “select those Requests whosepredecessor Activity mapped to a Request linked to the preceding Edge.”

Update LeftEdge of other Requests

UPDATE CnextRequests

SET LeftEdge=$edgeID

WHERE CNextRequests.RequestID=$RequestID

Select BarChart for export

SELECT * FROM [BarCharts] WHERE BarChartID=$BarChartID

Create Ordered Edge List

SELECT * FROM Edges

WHERE BarChartID=$BarChartID

ORDER BY Edges.EdgeNum

Select Requests for export

SELECT * FROM Requests

WHERE Requests.LeftEdge=$EdgeID

ORDER BY Requests.RequestOrder

Lookup Request Attributes

SELECT ControlAssemblyInstances.Label AS InstanceLabel,

DCCActions.Label AS ActionLabel,

DCCElementsTimes.Time

FROM Requests,

ControlAssemblyInstances AS Cai,

DCCActions,

DCCElementsTimes

WHERE Requests.RequestID=$RequestID

AND Requests.ControlAssemblyInstanceID=Cai.ControlAssemblyInstanceID

AND DCCActions.DCCActionsID=Requests.DCCActionsID

AND DCCElementsTimes.DCCActionsID=Requests.DCCActionsID

Enterprise Controls

Enterprise Controls (EC) is a single unifying construct for integratingcontrol system design, simulation, implementation, and maintenanceprocesses (via an integrated object model), and integrating controlsystem design and deployment with external product, process, and machinedata models (via an integrated enterprise-wide customer data model). TheDesigner Studio software provides enterprise control in accordance witha preferred embodiment.

This EC Designer Studio incorporates software from various new softwareincluding Enterprise Controls Designer Studio, a transfer machine model,status based diagnostics and code generation engine, a PanelBuildersoftware comprising: a layout editor and a layout compiler, RSWire(schematics), RSLadder (display and monitor LL), RS SoftLogix 5(simulator), RS Linx (communications gateway/router), PERL Scripting anda relational database such as Microsoft Access.

The EC Designer Studio utilizes Java 1.1, Visual J++ 6.0 and MicrosoftApplication Foundation Classes (version 2.5). FIG. 54 is a splash screenin accordance with a preferred embodiment. FIG. 55 is the initialdisplay for the Designer Studio in accordance with a preferredembodiment.

The Designer Studio integrates with External Data Models such asMechanical Resources panel which utilizes resources created within themechanical modeling environment to provide the resources that need to becontrolled. The data models can be based on “BIG” CAD (Unigraphics,SDRC, or CATIA) or “little” CAD (e.g., AutoCAD)] to determine theResources (Mechanical, Robotic, and Operator). An important part inaccordance with a preferred embodiment is a mechanism that determineswhich elements are to be controlled.

The Designer Studio also integrates a Mechanical Timing Diagram panelwhich can take on different dimensions based on the particular modelwhich is employed. For example, when CATIA is utilized, the sequence ofactivities that the resources perform in their process representation ofchoice are transformed into a Mechanical Timing Diagram in accordancewith a preferred embodiment. If AutoCad is utilized, then the DesignerStudio must create a Mechanical Timing Diagram.

This process is well suited for processes that use mechanical timingdiagrams to describe their sequence of operations. One of ordinary skillin the art will readily comprehend that real control system design isdone in small “chunks” that can be “rationalized” one at a time. Inaccordance with a preferred embodiment, these chunks will be referred toas Control Assemblies.

FIG. 56 illustrates a menu that is utilized to open a project inaccordance with a preferred embodiment. FIG. 57 illustrates a displaymenu that is utilized to select an existing project to load inaccordance with a preferred embodiment. FIG. 58

Illustrates an Open Project dialog in accordance with a preferredembodiment. A user interacts with this display to open a database andread a Mechanical Resources 5810 from the CAD database and transform theprocess description into a Mechanical Timing Diagram 5820.

One panel 5810 contains a hierarchical tree of the Resources for theIAM98 Workcell read from the CATIA CAD system and filtered to highlightcontrol information. A second panel 5820 contains a Mechanical TimingDiagram that performs the sequencing of the activities (or operations)that the resources perform. A third panel (Control Resources) 5800contains the Control Assembly Types that are selected by the EC DesignerStudio to be necessary for controlling the Mechanical Resources in thefinal panel Control Bar Chart 5830 that is populated automatically bythe system as control assemblies are created.

EC Control System Design

Control Engineers work on “small”, manageable “chunks” of the controlsystem. These chunks or control subsystems are referred to as ControlAssemblies as shown in panel 5800. Control Assemblies are created as afirst step in defining the enterprise control in accordance with apreferred embodiment. A control engineer creates Control Assemblies(i.e., small chunks of the control system) to control the mechanicalresources “that require control” (i.e., resources that have activitiesin the Mechanical Timing Diagram).

For example a user can create a Control Assembly of typeSafeBulkHeadClampSet 5840 in order to control clamps 2506A, 4502A,5508B, 5509A, 5516A, and 5516B. Note that SafeBulkHeadClampSet was oneof the Control Assembly Types predicted by the EC Designer Studio to beuseful to the user to control some of the resources in the MechanicalTiming Diagram as evidenced by its name appearing in the ControlResources window 5800.

These clamps perform the activities fixture (close) and release (open)in parallel on the Mechanical Timing Diagram. FIG. 59 illustrates a menudisplay for facilitating an “Add Control Assembly” dialog 5900 inaccordance with a preferred embodiment. FIG. 60 illustrates the firstmenu in an “Add Control Assembly” dialog in accordance with a preferredembodiment. The Add Control Assembly dialog provides a catalog ofreusable control sub-system components: Control Assembly Types (seebelow for the specification of a Control Assembly. In accordance withthe example, the Control Assembly Type selected is asafe-bulkheadclampset 6000.

After selecting the Type the user will click the New button. This userevent initiates the Control Assembly Wizard shown in FIG. 61 at 6100.

The Control Assembly Wizard allows a user to create a Confrol Assemblycorresponding to frequently used control subsystem design patterns andallows the user to actuate properties of that Control Assembly. FIGS. 61to 67 illustrate a user experience with a wizard in accordance with apreferred embodiment.

FIG. 62 illustrates a wizard display in which a control assembly hasbeen selected in accordance with a preferred embodiment. The user mustspecify a name for the new Control Assembly of Typesafe-bulkheadclampset as reflected at 6200.

In FIG. 63, the user specifies the name of the new control assembly inaccordance with a preferred embodiment. In the example, the name of thenew Control Assembly is 1stclamps. The Control Assembly Type is areusable component containing a number of user selectable properties (orparameters). 1stclamps is a specific instance of the component for whichthe user will set the properties. The Control Assembly Wizard defaultsare set to automatically create a schematic (i.e., wiring diagram or WD)for the assembly and all the available diagnostics (defined by the Type)for the assembly are preselected. Finally, the documentation format isdefaulted to HTML format.

An important feature of the system is the built in diagnostics anddocumentation that are architected into each component. This featureallows a control engineer to receive a predefined set of diagnosticsthat are carefully tailored to the characteristics of each component andbuild diagnostics right into the control system automatically. Moreover,as the system is simulated and ultimately brought into production, thediagnostics are available for integration and analysis from thebeginning of the process through the life of the system. Thus, when afailure occurs in the system, there are built-in controls thatfacilitate immediate identification of the failure and remedy. FIG. 64illustrates a resource selection display in accordance with a preferredembodiment. A user is presented with a list of available resources 6400from the Mechanical Timing Diagram that match the type of resource thatthe control assembly type 6410 can control and are not previously boundto other control assemblies.

FIG. 65 illustrates a selected set of controlled resources in accordancewith a preferred embodiment. The selected resources are shown in box6510 as they are selected from available resources shown at 6500. Theuser adds resources from the available list 6500 to the controlledresources list 6510 of the resources that will be controlled by thecontrol assembly 1stclamps of type safe-bulkheadclampset 6520.

FIG. 66 informs the user of the control components that will make up thecontrol assembly based on the resources chosen to be controlled inaccordance with a preferred embodiment. The control components 6600 andtheir labels 6610 are provided to assist the user in designing a controlstrategy. FIG. 67 illustrates the final step in defining controlassemblies in accordance with a preferred embodiment. The display window6700 presents a specification of the control assembly that will becreated if a user selects the Finish button.

FIG. 68 illustrates the processing that occurs when a user presses thefinish button in accordance with a preferred embodiment. First, theControl Assembly 1stClamps is added to the Control Resourceshierarchical tree panel in the ECDB. The parent of 1stClamps is theControl Assembly Type Safe-BulkHeadClampSet. The children of 1stClamps6810 are the requests or conditionals that determine the behavior of1stClamps. In this case 1stClamps has two requests: extend and retract6810.

The requests (extend and retract) 6810 corresponding to the activities(fixture and release) of the clamps controlled by 1stClamps areautomatically added to the Control Bar Chart panel 6840. The bars 6830denote the time period during which the extend and retract requestsoccur. The Control Bar Chart panel 6840 shows the sequence of requestsmade by the Control Assembly 1stClamps. The Control Bar Chart 6840 is acontrol system-wide tool that shows the sequence of Control Assemblyrequests.

There are relationships between the control assembly 1stClamps 6810, theMechanical Resources it controls, the Activities these resourcesperform, and the requests made by 1stClamps to these resources toinitiate their activities.

FIG. 69 illustrates the selection processing associated with aparticular control assembly in accordance with a preferred embodiment.To see these relationships a user selects 1stClamps 6910 in the ControlResources panel. This action highlights 6940 the clamps that 1stClampscontrols in the Mechanical Resources panel, the activities 6930 thatthese resources perform in the Mechanical Timing Diagram panel, and therequests made by 1stClamps to these resources to actuate theiractivities in the Control Bar Chart panel 6920.

Using the scroll bars we can arrange the Mechanical Timing Diagram andthe Control Bar Chart to see the sequencing relationship between theTiming Diagram of the Mechanical Resource activities and the requests ofthe 1stClamps control assembly. The activities of the clamps controlledby 1stClamps and the requests of 1stClamps occur in the same columns(i.e., during the same time period of the cycle).

FIG. 70 illustrates the processing of a control assembly in accordancewith a preferred embodiment. When a user clicks the mouse on the retract7000 request of 1stClamps the user can see the activities 7010controlled by the request. FIGS. 71 to 79 provide additional displays inaccordance with a preferred embodiment.

Schematic Tool: Allows user to add the control system-wide schematiccomponents such as factory services, rack layouts, . . . and to connectthe Control Assembly Instances electrically, pneumatically, andhydraulically via a control system-wide tool

e.g., RSWire adapted to work off an integrated data model that allows alocal (i.e., Control Assembly) schematic environment and a controlsystem-wide tool that connects Control Assemblies and adds theadditional schematics necessary to complete the Control System-widedesign (e.g., Factory Services, Rack Layouts, . . . ) HMI Tool: Allowsthe user to combine the viewable entities in the control assemblies tolayouts to monitor and control the process

EC Simulation

Visualization of the PLC LL execution is enabled by using RSLogix.Visualization of a current step(s) the machine is waiting onVisualization the “control process”, i.e., animate the Bar Chart. Usegenerated code via SoftLogix to animate in 3-D visualization of theworkcell machines in order to simulate the process and the subsequentcreation of the product Note: in EC all these simulations run off thesame data model.

EC Control System Implementation

Bill of materials (from RS Wire Schematics)

Make control system bill of materials and control system processavailable to the Machine and Process designers (i.e., export to CNext)

Code generation Tool

Diagnostics Generation Tool

HMI (Visualization) Generation Tool

EC Control System Maintenance

Diagnostics

Keeping control system design consistent with Product, Process, andMachine Design

Password protect to provide restricted access to RLL and the capabilityto record and changes that are made to the RLL that must be reengineeredinto the design.

A Control Assembly Component is a deployable control subsystem thatexposes an interface (to Control System-wide tools) that is acomposition of the following parts using a common object (or data) modeland is easily configurable by setting properties.

1 Control Components

1 Definition: a control component is an entity that either sends acontrol signal, receives a control signal, or both sends and receivescontrol signals.

These components control the flow of the motive forces (electrical,pneumatic, and hydraulic) that cause mechanical operations to occur.

2 Examples: solenoid valve (receives), proximity sensor (sends), Robotinterface (both), PanelView interface (both), pushbutton (sends),indicator light (receives), motor controller (both),

2 Mechanical Components

3 Definition: a mechanical component that is required to implement ordeploy the control subsystem (e.g., pneumatic hoses, check valves,

3 Logic

4 Definition: the logic specifies the control and fault states, thetransitions between states that the control components can attain (i.e.,the restricted state space of the control assembly), the controlleroutputs which produce the transitions, and inputs to the controllerdetermine the current state.

The following examples identify three types of logic groupings: inputonly, output only, and input/output.

5 Examples:

1 n-sensor PartPresent (input)

1 States

1 Part Absent

2 Part Present

3 Part out of position

2 Transitions

1 Part Absent=>Part Present

2 Part Present=>Part out of position

3 Part out of position=>Part Absent

4 Part Absent=>Part Present

5 Part Absent=>Part out of position

6 Part out of position=>Part Present

3 Outputs

1 None

4 Inputs

1 all n off (Part Absent)

2 all n on (Part Present)

3 k of n on (k<n, k>0) (Part out of position)

2 ClearToEnterLight (output) (e.g., single light also could be multiplelights)

1 States

1 LightOn

2 LightOff

2 Transitions

1 LightOn=>LightOff

2 LightOff=>LightOn

3 Outputs

1 LightOnSignal (LightOff=>Lighton)

2 Not LightOnSignal (LightOn=>LightOff)

3 SafeBulkHeadClamp (both)

1 States

1 Retracted

2 Extended

3 Between

2 Transitions

1 Retracted=>Between

2 Between=>Extended

3 Extended=>Between

4 Between=>Retracted

3 Outputs

1 Extend (both valves opened=4 outputs high)

2 Retract (main valve closed=2 outputs high)

4 Inputs

1 Retracted (retract proximity sensors on for all cylinders)

2 Extended (extend proximity sensors off for all cylinders)

3 Between (one or more sets of proximity sensors both off)

4 Fault 1 (one set of proximity sensors both on)

5 Fault 2 (one or more of the set of sensors disagrees with the othersfor a nominally significant time period).

4 Diagnostics

6 Definition: Status-based diagnostics—specifies the step(s) that themachine is currently waiting to occur (if a fault occurs it specifiesthe step(s) that were waiting to occur at the time of the fault, i.e.,the symptoms).

Note: this information is available for both well behavior and faultbehavior.

7 Definition2: Causal model-based diagnostics—use a model of causalrelationships to develop rules that relate machine status to rootcauses.

8 Examples:

1 Consider that a human mechanic has incorrectly moved the mountlocation of a part present proximity sensor causing a misalignment.

1 Status-based: determines that the machine is “waiting for part presentsensor #2” (no automatic inference possible)

2 Consider that the proximity sensor on a clamp cylinder has failed

1 Status-based: determines that machine is “waiting for clamp cylinder2504A”

2 Causal model-based: logic infers that the extend proximity sensor oncylinder 2504A has failed, or that cylinder 2504A is stuck.

5 Schematics

9 Definition: a schematic is a representation of the electrical,pneumatic, and hydraulic interface to the control assembly.

Examples:

1 Ielectrical

2 Ipneumatic

3 Ihydraulic

4 . . .

6 Visualization

11 Definition: entities within the control assembly that are useful toportray textually or graphically.

12 Examples:

1 Control Components (textually or graphically)

2 Logic (graphically: RLL, Function Blocks, Axis-like diagrams, statediagrams . . . ) what ever conveys the logic to the user.

3 Diagnostics

1 Status messages

2 Causal messages

4 Schematics

1 Typed connections (electrical, pneumatic, network, . . . ) withinControl Assembly and to and from the Control Assembly (i.e., theinterface to the Control Assembly.

2 Bill of Materials (to deploy the control assembly)

3 . . .

5 Controlled Resources

6 Requests

7 Controlled Resources

13 Definition: properties of the resource controlled by the controlassembly that place requirements (i.e., add constraints) on thestructure of the assembly

14 Example

1 Clamp 1

1 Safety constraint: if lose power clamp must fail open

8 Requests or Conditions

15 Definition: request an operation (optionally with confirmation) orrequest a status of the external world (color code)

1 Request Action Request Status

2 Request Action

3 Request Status

4 Note: how to handle complicated actions (initialization, robotprotocols, . . . )

16 Examples:

1 PartPresent

1 SensePart (Request Status)

2 ClearToEnterLight

1 TurnOn (Request Action)

2 TurnOff (Request Action)

3 SafeBulkHeadClamp

1 Extend

2 Retract

4 SafetyGate

1 SenseSafe (Request Status)

9 Documentation

Control Bar Chart panel: Allows user to sequence the Requests of ControlAssembly Instances via a control system-wide tool called a Control BarChart.

Schematic Tool: Allows user to add the control system-wide schematiccomponents such as factory services, rack layouts, . . . and to connectthe Control Assembly Instances electrically, pneumatically, andhydraulically via a control system-wide tool

e.g., RSWire adapted to work off an integrated data model that allows alocal (i.e., Control Assembly) schematic environment and a controlsystem-wide tool that connects Control Assemblies and adds theadditional schematics necessary to complete the Control System-widedesign (e.g., Factory Services, Rack Layouts, . . . )

HMI Tool: Allows the user to combine the viewable entities in thecontrol assemblies to layouts to monitor and control the process

EC Simulation

Visualization of the LL execution is facilitated through the use ofRSLogix (RSLadder is better)

Visualization the current step(s) the machine is waiting on

Visualization the “control process”, i.e., animate the Bar Chart

Use generated code via SoftLogix to animate in 3-D visualization of theworkcell machines in order to simulate the process and the subsequentcreation of the product

Note: in EC all these simulations run off the same data model.

EC Control System Implementation

Bill of materials (from RS Wire Schematics)

Make control system bill of materials and control system processavailable to the Machine and Process designers (i.e., export to CNext)

Code generation Tool

Diagnostics Generation Tool

HMI (Visualization) Generation Tool

EC Control System Maintenance

Diagnostics

Keeping control system design consistent with Product, Process, andMachine Design

Password protect to provide restricted access to LL and the capabilityto record and changes that are made to the LL that must be reengineeredinto the design.

Definition: a Control Assembly Component is a deployable controlsubsystem that exposes an interface (to Control System-wide tools) thatis a composition of the following parts using a common object (or data)model and is easily configurable by setting properties. FIG. 80 is ablock diagram of a control assembly in accordance with a preferredembodiment. The boxed region designates the control assembly componentwhich is a container. The control assembly component is a composition ofa logic class 8010, a diagnostics class 8030, schematics class 8020,Human Machine Interface (HMI) class 8032 and a control model 8000. Thecontrol model 8000 which contains the common fields and methods (logic)for a control assembly class. The logic 8010 is a class that containsthe fields and methods that are unique to the logic portions of acontrol assembly type. The diagnostics class 8030 is a class thatcontains the fields and methods that are unique to the diagnosticsportions of a control assembly type. The schematics class 8020 is aclass that contains the fields and methods that are unique to theschematics portions of a control assembly type. The HMI class 8032 is aclass that contains the fields and methods that are unique to the userinterface portions of a control assembly type.

The IRequest interface 8086 specifies the external behavior methods(logic) for controlling a controlled resource. For example, the messagethat invokes the logic for opening and closing a clamp. The IViewinterface 8080 specifies the external behavior methods (logic) forviewing schematics (electrical, hydraulic and pneumatic). The IBOMinterface 8084 specifies the external behavior methods (logic) forretrieving the Bill-Of-Materials (BOM) for a control assembly component.The INetlist interface 8082 specifies the external behavior methods(logic) for retrieving the electrical, pneumatic and hydraulicconnections between the control and mechanical devices within a controlassembly component.

The IRender interface 8070 specifies the external behavior method(logic) for retrieving viewable elements and their properties andgenerating a user interface. The IDocument interface 8060 specifies theexternal behavior method (logic) for producing documentation of thecontrol assembly component. The IControl interface 8050 specifies theexternal behavior method (logic) for retrieving the resources that thecontrol assembly component is capable of controlling. The IDiagnosticsinterface 8040 specifies the external behavior method (logic) forselecting diagnostics that are instantiated for a control component.

10 Control Components

17 Definition: a control component is an entity that either sends acontrol signal, receives a control signal, or both sends and receivescontrol signals.

These components control the flow of the motive forces (electrical,pneumatic, and hydraulic) that cause mechanical operations to occur.

18 Examples: solenoid valve (receives), proximity sensor (sends), Robotinterface (both), PanelView interface (both), pushbutton (sends),indicator light (receives), motor controller (both),

11 Mechanical Components

19 Definition: a mechanical component that is required to implement ordeploy the control subsystem (e.g., pneumatic hoses, check valves,

12 Logic

1 Definition: the logic specifies the control and fault states, thetransitions between states that the control components can attain (i.e.,the restricted state space of the control assembly), the controlleroutputs which produce the transitions, and inputs to the controllerdetermine the current state.

The following examples identify three types of logic groupings: inputonly, output only, and input/output.

2 Examples:

1 n-sensor PartPresent (input)

1 States

1 Part Absent

2 Part Present

3 Part out of position

2 Transitions

1 Part Absent=>Part Present

2 Part Present=>Part out of position

3 Part out of position=>Part Absent

4 Part Absent=>Part Present

5 Part Absent=>Part out of position

6 Part out of position=>Part Present

3 Outputs

1 None

4 Inputs

1 all n off (Part Absent)

2 all n on (Part Present)

3 k of n on (k<n, k>0) (Part out of position)

2 ClearToEnterLight (output) (e.g., single light also could be multiplelights)

1 States

1 LightOn

2 LightOff

2 Transitions

1 LightOn=>LightOff

2 LightOff=>LightOn

3 Outputs

1 LightOnSignal (LightOff=>LightOn)

2 Not LightOnSignal (LightOn=>LightOff)

3 SafeBulkHeadClamp (both)

4 States

1 Retracted

2 Extended

3 Between

5 Transitions

1 Retracted=>Between

2 Between=>Extended

3 Extended=>Between

4 Between=>Retracted

6 Outputs

1 Extend (both valves opened=4 outputs high)

2 Retract (main valve closed=2 outputs high)

7 Inputs

1 Retracted (retract proximity sensors on for all cylinders)

2 Extended (extend proximity sensors off for all cylinders)

3 Between (one or more sets of proximity sensors both off)

4 Fault 1 (one set of proximity sensors both on)

5 Fault 2 (one or more of the set of sensors disagrees with the othersfor a nominally significant time period).

13 Diagnostics

1 Definition: Status-based diagnostics—specifies the step(s) that themachine is currently waiting to occur (if a fault occurs it specifiesthe step(s) that were waiting to occur at the time of the fault, i.e.,the symptoms).

Note: this information is available for both well behavior and faultbehavior.

2 Definition2: Causal model-based diagnostics—use a model of causalrelationships to develop rules that relate machine status to rootcauses.

3 Examples:

3 Considerthat a human mechanic has incorrectly moved the mount locationof a part present proximity sensor causing a misalignment.

1 Status-based: determines that the machine is “waiting for part presentsensor #2” (no automatic inference possible)

4 Consider that the proximity sensor on a clamp cylinder has failed

1 Status-based: determines that machine is “waiting for clamp cylinder2504A”

2 Causal model-based: logic infers that the extend proximity sensor oncylinder 2504A has failed, or that cylinder 2504A is stuck.

14 Schematics

1 Definition: a schematic is a representation of the electrical,pneumatic, and hydraulic interface to the control assembly.

2 Examples:

5 Ielectrical

6 Ipneumatic

7 Ihydraulic

8 . . .

15 Visualization

20 Definition: entities within the control assembly that are useful toportray textually or graphically.

21 Examples:

1 Control Components (textually or graphically)

2 Logic (graphically: LL, Function Blocks, Axis-like diagrams, statediagrams . . . ) what ever conveys the logic to the user.

3 Diagnostics

1 Status messages

2 Causal messages

4 Schematics

1 Typed connections (electrical, pneumatic, network, . . . ) withinControl Assembly and to and from the Control Assembly (i.e., theinterface to the Control Assembly.

2 Bill of Materials (to deploy the control assembly)

3 . . .

5 Controlled Resources

6 Requests

16 Controlled Resources

22 Definition: properties of the resource controlled by the controlassembly that place requirements (i.e., add constraints) on thestructure of the assembly

23 Example

1 Clamp 1

1 Safety constraint: if lose power clamp must fail open

17 Requests or Conditions

24 Definition: request an operation (optionally with confirmation) orrequest a status of the external world (color code)

1 Request Action Request Status

2 Request Action

3 Request Status

4 Note: how to handle complicated actions (initialization, robotprotocols, . . . )

25 Examples:

1 PartPresent

1 SensePart (Request Status)

2 ClearToEnterLight

1 TurnOn (Request Action)

2 TurnOff (Request Action)

3 SafeBulkHeadClamp

1 Extend

2 Retract

4 SafetyGate

1 SenseSafe (Request Status)

18 Documentation

While the invention is described in terms of preferred embodiments in aspecific system environment, those skilled in the art will recognizethat the invention can be practiced, with modification, in other anddifferent hardware and software environments within the spirit and scopeof the appended claims.

To apprize the public of the scope of this invention, the followingclaims are made:

What is claimed is:
 1. A method to be used with a simulator and acontroller, the controller for running execution code to provide outputsignals which, when linked to manufacturing tools, cause themanufacturing tools to cycle through requested activities, the simulatorfor receiving controller output signals and, in response thereto,generating motion pictures of manufacturing tools as the manufacturingtools cycle through requested activities, the simulator using datastructures which model the manufacturing tools to determine which motionpictures to generate, the method for generating execution code and datastructures for use by the controller and the simulator, respectively,and comprising the steps of: for each manufacturing tool, encapsulatingmanufacturing tool information including manufacturing tool logic in acontrol assembly (CA); instantiating at least one instance of at leastone CA; compiling instantiated CA instance manufacturing tool logic togenerate execution code for controlling manufacturing tools; gleaningsimulation information from the instantiated CA instances; and using thegleaned simulation information to generate a simulation data structurefor the manufacturing tools corresponding to the instantiated CAinstances.
 2. The method of claim 1 further including the step ofproviding the execution code and the data structures to the controllerand the simulator, respectively.
 3. The method of claim 1 wherein thestep of encapsulating also includes encapsulating simulation informationcorresponding to the manufacturing tools in corresponding CAS andwherein the step of gleaning includes retrieving the simulationinformation.
 4. The method of claim 3 wherein the controller is aprogrammable logic controller which provides I/O combination outputsignals, the simulator is a movie module which displays video clips, theencapsulated simulation information includes I/O combinations correlatedwith specific video clips in a table and the step of gleaning includesaccessing the table and retrieving the correlated combination/clipinformation.
 5. The method of claim 4 wherein the controller alsoaccepts feedback signals, the encapsulated simulation informationfurther includes I/O feedback combinations correlated with specificsimulation events in a feedback table and the step of gleaning includesaccessing the feedback table and retrieving the correlated feedbackcombination/simulation event information.
 6. The method of claim 1wherein the gleaned information includes a first simulation informationset and the method further includes the step of, for each of at least asubset of the CAS, encapsulating a second simulation information set ina data structure template and, wherein the step of using the gleanedinformation includes the step of combining the first and secondsimulation information sets for each instantiated CA to generate aseparate data structure for each instantiated CA.
 7. The method of claim6 wherein a separate manufacturing tool set corresponds to each CA,operation of each separate manufacturing tool is dependent on bothuniversal characteristics and circumstantial characteristics, universalcharacteristics being characteristics which are identical for allmanufacturing tools of the specific type and circumstantialcharacteristics being characteristics which may vary betweenmanufacturing tools wherein the manufacturing tools are of the same typeand, wherein the first simulation information set includes universalcharacteristics and the second simulation information set includescircumstantial characteristics.
 8. The method of claim 6 whereinmanufacturing tool operation during activities is dependent onmanufacturing tool environment and each second simulation informationset models a manufacturing tool environment.
 9. The method of claim 6wherein manufacturing tool operation during activities is dependent onmanufacturing tools characteristics and each second simulationinformation set models manufacturing tool characteristics.
 10. Themethod of claim 6 further including the step of, prior to compiling,sequencing requested activities and, wherein, manufacturing tooloperation during activities is dependent on prior activities and eachsecond simulation information set includes information indicating prioractivities and modeling the effects of prior activities on manufacturingtool operation.
 11. The method of claim 1 wherein the step ofinstantiating includes indicating specific characteristics about themanufacturing tool corresponding to the CA instance.
 12. The method ofclaim 11 wherein the step of indicating specific characteristicsincludes the step of selecting a subset of resources, the step ofcompiling includes compiling execution code for the subset and the stepof gleaning includes gleaning information for the subset.
 13. A controlassembly (CA) set to be used with a compiler, a simulator and acontroller, the controller for running execution code to provide outputsignals which, when linked to manufacturing tools, cause themanufacturing tools to cycle through requested activities, the simulatorfor receiving controller output signals and, in response thereto,generating motion pictures of manufacturing tools as the manufacturingtools cycle through the requested activities, the simulator using datastructures which model the manufacturing tools to determine which motionpictures to generate, the compiler for compiling manufacturing toolsinformation to generate execution code and data structures, the CA setincluding a separate information construct type for each manufacturingtools, each CA type for encapsulating information required to generateexecution code and at least a subset of the information required togenerate a data structure for simulating a corresponding manufacturingtool, the CA set comprising: a plurality of CAs, each CA including: alogic specification which specifies logic corresponding to themanufacturing tools associated with the CA; and a simulationspecification which specifies simulation information corresponding tothe manufacturing tools associated with the CA.
 14. The set of claim 13also for use with an editor and wherein each logic specificationincludes logic characteristics, logic characteristics corresponding toat least a subset of CAS are parameterizable using the editor andwherein each CA further includes a recording means for recordingparameterization.
 15. The set of claim 14 wherein the recording means isa plurality of flag boxes.
 16. The set of claim 13 wherein a separatemanufacturing tool set corresponds to each CA, operation of amanufacturing tool set corresponding to a specific CA type is dependenton both universal characteristics and circumstantial characteristics,universal characteristics being characteristics which are identical forall CAs of the specific type and circumstantial characteristics beingcharacteristics which may vary from manufacturing tool set tomanufacturing tool set and, wherein, the simulation specificationspecifies a characteristic subset of the universal and circumstantialcharacteristics.
 17. The set of claim 16 wherein the characteristicsubset includes the universal characteristics.
 18. The set of claim 13wherein the controller is a programmable logic controller whichgenerates I/O combination output signals, the simulator is a moviemodule which generates video clips and each simulation specificationcorrelates video clips with I/O output combinations.
 19. The set ofclaim 18 wherein the controller also accepts feedback signals and eachsimulation specification further includes I/O feedback combinationscorrelated with specific simulation events in a feedback table.
 20. Anapparatus to be used with a system, the system including a simulator, acontrol assembly (CA) set, a controller and a specifier, the controllerfor running execution code to provide output signals which, when linkedto manufacturing tools, cause the manufacturing tools to cycle throughrequested activties, the simulator for receiving controller outputsignals and, in response thereto, generating motion pictures ofmanufacturing tools as the manufacturing tools cycle through requestedactivities, the simulator using data structures which model themanufacturing tools to determine which motion pictures to generate, a CAbeing a data construct which encapsulates logic information for acorresponding manufacturing tool, the CA set including a separate CA foreach manufacturing tool supported by the system, the editor forinstantiating at least one instance of at least one CA, the apparatusfor generating execution code and data structures for use by thecontroller and the simulator, respectively, and comprising: a processorfor executing a pulse sequenced program to perform the steps of:compiling instantiated CA instance manufacturing tool logic to generateexecution code; gleaning simulation information from the instantiated CAinstances; and using the gleaned simulation information to generate asimulation data structure for the manufacturing tools corresponding tothe instantiated CA instances.
 21. The apparatus of claim 20 wherein theprocessor executes the pulse sequenced program to further perform thestep of providing the execution code and the data structures to thecontroller and the simulator, respectively.
 22. The apparatus of claim20 wherein each CA also encapsulates simulation informationcorresponding to the CA manufacturing tools and wherein the processorgleans by retrieving the simulation information.
 23. The apparatus ofclaim 22 wherein the controller is a programmable logic controller whichprovides I/O combination output signals, the simulator is a movie modulewhich displays video clips, the encapsulated simulation informationincludes I/O combinations correlated with specific video clips in atable and wherein the processor gleans by accessing the table andretrieving the correlated combination/clip information.
 24. Theapparatus of claim 23 wherein the controller also accepts feedbacksignals, the encapsulated simulation information further includes I/Ofeedback combinations correlated with specific simulation events in afeedback table and the processor gleans by accessing the feedback tableand retrieving the correlated feedback combination/simulation eventinformation.
 25. The apparatus of claim 20 wherein the gleanedinformation includes a first simulation information set and at least asecond simulation information set is accessible to the processor and theprocessor performs the step of using the gleaned information bycombining the first and second simulation information sets for eachinstantiated CA to generate a separate data structure for eachinstantiated CA.
 26. The apparatus of claim 25 wherein a separateresource set corresponds to each CA, operation of each separate resourceis dependent on both universal characteristics and circumstantialcharacteristics, universal characteristics being characteristics whichare identical for all resources of a specific type and circumstantialcharacteristics being characteristics which may vary between resourceswherein the resources are of the same type and, wherein, the firstsimulation information set includes universal characteristics and thesecond simulation information set includes circumstantialcharacteristics.